OPERATOR'S MANUAL

Ref no VOE 2126696832 English

Printed in Sweden CST
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.

California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.
 L150E/L180E OPERATOR'S MANUAL
Foreword
This Operator's Manual is intended as a guide for the correct Table of contents
use and maintenance of the machine. Therefore, study it
carefully before starting and operating the machine, or before
carrying out any preventive maintenance.
Keep the manual in the cab so that it is always at hand. Re-
place it immediately, if it is lost. Presentation
The manual describes the applications for which the machine
primarily is intended and is written to apply for all markets. We
therefore ask you to disregard the sections which are not ap-
plicable to your machine or to the work for which you use your Instrument panels
machine.
NOTE: The information in the manual applies to both ma-
chine types, L150E and L180E, unless otherwise stated.

Many hours are spent on design and production to make a Other controls
machine that is as efficient and safe as possible. The acci-
dents which occur in spite of this, are mostly caused by the
human factor. A safety conscious person and a well main-
tained machine make a safe, efficient and profitable combina-
tion. Therefore, read the safety instructions and follow Operating instructions
them.
We continually strive to improve our products and to make
them more efficient through changes to their design. We re-
tain the right to this without committing ourselves to introduc-
ing these improvements on products, which have already Operating techniques
been delivered. We also retain the right to change data and
equipment, as well as instructions for service and other main-
tenance measures without prior notice.

Safety when servicing

Safety regulations
It is the operator's obligation to know and follow the applica-
ble national and local safety regulations. The safety instruc-
tions in this manual only apply to cases when there are no Basic preventive maintenance
national or local regulations.

Specifications

The symbol above appears at various points in the man- Alphabetical index
ual together with a warning text. It means:
Warning, be alert! Your safety is involved! It is the obliga-
tion of the operator to make sure that all warning decals
are in place on the machine and that they are readable.
Accidents may otherwise occur.

Get to know the capacity and limits of your

machine!

Ref. No.: VOE 2126696832

Printed in Sweden 02.06
 Foreword
2 Identification numbers

Identification numbers
State the identification number of the machine and the components below. The number should be stated when
contacting the manufacturer and when ordering spare parts. The position of the plates is shown on page 8.

Manufacturer Volvo Wheel Loaders AB

SE-631 85 Eskilstuna
Sweden

Machine product identifi-

cation number

Engine

Transmission

Front axle

Rear axle

Lifting frame

Cab

Key, cab door/ignition

switch

Key, filler cap

 Table of contents
3

Table of contents
Foreword....................................................................1
Identification numbers ............................................................ 2
Table of contents ......................................................3
Presentation ..............................................................5
CE marking, EMC directive .................................................... 7
Product plates......................................................................... 8
Information and warning plates / decals ................................. 9
The USA Federal Clean Air Act............................................ 14
Instrument panels ...................................................17
Right instrument panel.......................................................... 18
Front right instrument panel.................................................. 24
Centre instrument panel ....................................................... 26
Front left instrument panel.................................................... 33
Display unit ........................................................................... 35
Alarm texts............................................................................ 44
Other controls .........................................................49
Controls ................................................................................ 49
Boom kick-out and bucket positioner.................................... 56
Operator comfort .................................................................. 57
Operating instructions ...........................................65
Safety rules when operating ................................................. 66
Measures before operating................................................... 70
Starting engine ..................................................................... 71
Steering ................................................................................ 75
Braking ................................................................................. 77
Stopping machine................................................................. 79
Parking ................................................................................. 80
Recovering/towing ................................................................ 81
Transporting machine........................................................... 84
Operating techniques .............................................85
Attachments.......................................................................... 86
Attaching and disconnecting attachments ............................ 87
Accumulators, releasing pressure ........................................ 90
Buckets................................................................................. 91
Timber grapples.................................................................... 95
Pallet forks............................................................................ 98
Material handling arm ......................................................... 100
Rotating attachments.......................................................... 102
Signalling diagram .............................................................. 103
Getting stuck....................................................................... 106
Safety when servicing ..........................................107
Service position .................................................................. 107
Before service read ............................................................ 108
 Table of contents
4

Basic preventive maintenance ............................115

Service points, L150E......................................................... 116
Service points, L180E......................................................... 117
Engine ................................................................................ 118
Fuel system ........................................................................ 120
Turbocharger ...................................................................... 124
Air cleaner .......................................................................... 125
Oil-bath precleaner (optional equipment) ........................... 126
Cooling system ................................................................... 127
Electrical system................................................................. 131
Transmission ...................................................................... 136
Front and rear axles ........................................................... 138
Brake system...................................................................... 140
Cab ..................................................................................... 142
Operator seat, lubrication ................................................... 144
Air conditioning (optional equipment) ................................. 145
Hydraulic system ................................................................ 147
Tyres................................................................................... 149
Greasing bearings .............................................................. 150
Service schedule ................................................................ 151
Lubrication and service chart, L150E ................................. 152
Lubrication and service chart, L180E ................................. 156
Automatic greasing............................................................. 160
Specifications........................................................167
Recommended lubricants................................................... 167
Capacities L150E ............................................................... 169
Engine L150E ..................................................................... 170
Electrical system L150E ..................................................... 171
Power transmission L150E................................................. 174
Axle oils L150E................................................................... 175
Brakes / steering system L150E......................................... 177
Recommended air pressure L150E.................................... 178
Cab L150E.......................................................................... 179
Hydraulic system L150E..................................................... 180
Dimensional drawing L150E............................................... 181
Machine capacity L150E .................................................... 182
Timber grapple L150E ........................................................ 183
Capacities L180E ............................................................... 184
Engine L180E ..................................................................... 185
Electrical system L180E ..................................................... 186
Power transmission L180E................................................. 189
Axle oils L180E................................................................... 190
Brakes / steering system L180E......................................... 192
Recommended air pressure L180E.................................... 193
Cab L180E.......................................................................... 194
Hydraulic system L180E..................................................... 195
Dimensional drawing L180E............................................... 196
Machine capacity L180E .................................................... 197
Timber grapple L180E ........................................................ 198
Alphabetical index ................................................199
 Presentation
5

Presentation

L180 E
L150 E
L68576A

Intended use
The machine is intended to be used under normal conditions for
the applications described in the Operator's Manual. If it is used for
other purposes or in potentially dangerous environments, for ex-
ample explosive atmosphere or areas with dust containing asbes-
tos, etc., special safety regulations must be followed and the
machine be equipped for such use. Contact the manufacturer/
dealer for further information.
The machine is designed for a maximum machine weight (incl.
equipment and attachments) of 31000 kg (68343 lb). If the maxi-
mum weight is exceeded, safety will be jeopardized. In addition, no
warranties on the part of the manufacturer will apply. Always pay
attention to national regulations for travelling on public roads.
Engine
L150E
Volvo D10BLAE2 is a 9.6 litre (586 in3), six-cylinder, four-stroke,
direct-injection, low-emission engine which is turbocharged with
intercooling of the air to air type. The injection pump is of the in-line
type and is electronically controlled via an electronic control unit
(E-ECU). The engine has wet, replaceable cylinder liners and two
valves per cylinder with replaceable valve guides and valve seat
inserts. The accelerator position is transferred electrically from the
accelerator pedal and hand throttle (optional equipment) to the
control unit (E-ECU).
L180E
Volvo D12CLCE2 is a 12.13 litre (740 in3), six-cylinder, four-stroke,
direct-injection low-emission engine which is turbocharged with in-
tercooling of the air to air type.The fuel system is electronically
controlled via a control unit (E-ECU) and has one unit injector for
each cylinder. The fuel injection pressure is obtained from the
overhead camshaft. The engine has wet, replaceable cylinder lin-
ers and four valves per cylinder with replaceable valve guides and
valve seat inserts. The accelerator position is transferred electri-
cally from the accelerator pedal and hand throttle (optional equip-
ment) to the control unit (E-ECU).
Electrical system
The machine has three control units (ECUs). The I-ECU for the in-
strumentation is integrated with the display unit, warning lamps
and instruments and provides the operator with information via
these.
The V-ECU (for the machine) receives signals from sensors on the
machine and these are passed on to the I-ECU and E-ECU. V-
ECU is placed in the electrical distribution box on the cab´s back
wall.
The E-ECU controls the engine. It is placed on the engine.
 Presentation
6

Power transmission
The transmission is electro-hydraulically controlled, where all
gears are in constant mesh. The gear ranges are achieved by ap-
plying different combinations of clutches. Between engine and tim-
ing gears there is an hydraulic torque converter, which steplessly
controls the output torque. The front and rear axles have planetary
gears in the wheel hubs and this reduces the strain on the respec-
tive drive shafts. The axles are of the AWB type (Axle Wet Brakes).

Brake system
The machine is provided with a dual-circuit all-hydraulic brake sys-
tem with one circuit for each axle. Each circuit meets the require-
ments for secondary brake capability. The brakes are of the wet
disc brake type and they are cooled with oil circulating in the axle.
The brakes may also be provided with external oil cooler and cir-
culation pump (optional equipment).

Parking Brake
The parking brake is a wet multi-disc brake built into the transmis-
sion. The brake is electro-hydraulically controlled and applied by
spring force and is released hydraulically.

Steering system
The machine is provided with a load-sensing, hydrostatic steering
system and has a steering arc of ±37°.

Cab
The cab has a heating and ventilation system with defrosting for all
windows. Air conditioning is available as optional equipment. The
cab has an emergency exit, the right side window.

FOPS and ROPS

The cab is approved as a protective cab according to the FOPS
and ROPS standards, see pages 179 and 194. FOPS is an abbre-
viation of Falling Object Protective Structure (roof protection) and
ROPS is an abbreviation of Roll Over Protective Structure (roll
over protection).
Never carry out any unauthorised alterations to the cab, e.g. low-
ering the roof height, drilling, welding on brackets for fire extin-
guisher, radio aerial or other equipment, without first having
discussed the alteration with personnel at the Volvo Engineering
Department. This department will decide whether the alteration
may cause the approval to become void. It is important that all par-
ties concerned are ware of these regulations.

Hydraulic system
The hydraulic system is load-sensing with pumps in common to
the brake, servo- and steering systems and the working hydrau-
lics. However, the brake and steering systems are prioritised by
one of the pumps.

Equipment
The machine can be provided with different types of optional
equipment, depending on the requirements of different markets.
Examples of such equipment are lever steering (CDC), Boom Sus-
pension System (BSS), secondary steering, separate attachment
locking, automatic greasing (standard on certain markets).
 Presentation
CE marking, EMC directive 7

CE marking, EMC directive

CE marking
(Declaration of Conformity applies only to machines market-
ed within the EU/EEA).
This machine is CE marked. This means that when delivered the
machine meets the applicable "Essential Health and Safety Re-
quirements", which are given in the EU Machinery Safety Direc-
tive, 98/37/EC.
L64437A Any person carrying out changes that affect the safety of the ma-
chine, is also responsible for the same.
As proof that the requirements are met, the machine is supplied
with an EU Declaration of Conformity, issued by Volvo CE for each
separate machine. This EU declaration also covers attachments
manufactured by Volvo CE. The documentation is a valuable doc-
ument, which should be kept safe and retained for at least ten
years. The document should always accompany the machine
when it is sold.
If the machine is used for other purposes or with other attachments
than described in this manual, safety must at all times and in each
separate case be maintained. The person carrying out such action
is also responsible for the action which, in some cases, may re-
quire a new CE marking and the issue of a new EU Declaration of
Conformity.
EU EMC Directive
The electronic equipment of the machine may in some cases
cause interference to other electronic equipment, or suffer from ex-
ternal electromagnetic interference, which may constitute safety
risks.
The EU EMC directive about "Electromagnetic compatibility", 89/
336/EEC, provides a general description of what demands can be
made on the machine out of a safety point of view, where permitted
limits have been determined and given according to international
standards.
A machine or device which meets the requirements should be CE
marked. Our machines have been tested particularly for electro-
magnetic interference. The CE marking of the machine and the
declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the equip-
ment must be CE marked and tested on the machine with regard
to electromagnetic interference.
 Presentation
8 Product plates

Product plates
With the aid of the product plates, shown below, it is possible to identify the machine and its components. The
Product Identification Number, PIN, indicates the model designation, engine code and serial number of the ma-
chine. The Component Identification Number, CIN, indicates the serial number of the component. Make a note of
the identification numbers on page 2.
When ordering spare parts, and in all telephone enquiries or correspondence the PIN and CIN must always be
quoted.
1 2 3 5 6
4

L68967A
7 8 9

1 Lifting frame 6 Engine

The manufacturer's name and address and the lifting The engine type designation and number (stamped-in
frame CIN. on the engine).
2 Primary marking 7 Front axle
The machine PIN (stamped-in on the right side). The manufacturer's name and address and front drive
axle CIN.
3 Product plate 8 Transmission
The manufacturer's name and address, machine PIN. The manufacturer's name and address and transmis-
sion CIN.
4 Additional plate for product plate 9 Rear axle
Machine weight, engine output, year of manufacture, The manufacturer's name and address and rear drive
year of delivery and position of CE mark (EU/EEA axle CIN.
countries only).
5 Cab
The manufacturer's name and address, product
number, machine model designation, max. machine
weight, cab serial number, ROPS/FOPS number and
ROPS/FOPS certificate number.
 Presentation
Information and warning plates / decals 9

Information and warning plates / decals

The operator should know and pay attention to the information and warning plates / decals which are positioned
on the machine. All plates/decals are not installed on all machines, as they are market and machine dependent.
The decals/plates must be kept free from dirt, so that they can be read and understood. If they have been lost or
no longer are legible, they must be replaced immediately. The part number (order number) is given on the respec-
tive plates/decals and in the Parts Catalogue.
 Presentation
10 Information and warning plates / decals

L67524A

L67521A
13935003 13935001

1 WARNING! First read the Operator's Manual 2 WARNING! Rotating fan.

WARNING

L67523A
L67534A

13 935 006 11 111 506

3 WARNING! Reversing machine 4 WARNING! Check that the attachment is locked

L67528A
L67532A

13935000 13935002

5 WARNING! Warning, risk of crushing at frame 6 WARNING! Do not walk under raised attachment
joint if machine is steered
L67533A
L67600A

11026072
4948092

7 WARNING! Do not step on this surface 8 WARNING! Pressurised system

WARNING

CDC
L67535A

13935004
L67529A

11 104 133

9 WARNING! When travelling on a public road, it is 10 WARNING! Before connecting jump leads – read
prohibited to have the lever steering (CDC) acti- the Operator's Manual
vated – use the steering wheel
 Presentation
Information and warning plates / decals 11

4932797
4952173

4948103
L67540A

L67542A
L67541A

11 Hydraulic oil level 12 Coolant filling point 13 Hydraulic oil filling point

L67585A
L67527A
L67543A

13935007 13935005
11055037

14 Fuel filling point 15 Emergency exit 16 Avoid directing water jet

against air intake

11 026 730
L67530A
L67579A

L67538A

11180010

17 Engine oil filling point 18 Battery disconnect switch 19 Attaching point for lashing

L WA L pA
dB 495
4898

dB
L67551A 00000000 L67552A

20 Sound power level outside the 21 Sound pressure level in cab

machine 22 Point for lifting

L67601A

2534201

25 Draining point
L67583A

11025844 4952181

23 Synthetic ester 24 Anti-freeze

NOTICE: R134a AC-SYSTEM

System designed acc. to SAE J639 rev.nov91

Caution: System to be servised by Volvo qualified personel.

See Volvo service instruction.
L67526A

Volvo Construction Equipment 11104071

L67525A

4952167

26 Refrigerant R134a
27 Air cleaner – read the Opera-
tor's Manual
 Presentation
12 Information and warning plates / decals

TRANSMISSION DROPBOX TRANSMISSION

L67539A
4932840

30 Transmission
L67570A

L67569A
11090495 11090496

28 Transmission 29 Dropbox
L68091A

11130942

31 Transmission
L67531A

32 Lubrication and service chart

 Presentation
Information and warning plates / decals 13

The decals below are only used in the USA.

 WARNING  WARNING
SPRING UNDER PRESSURE. DISCONNECT STEERING
REFER TO OPERATORS AND FRAME LOCK BEFORE
SERVICE MANUAL FOR THIS
MOVING MACHINE

L67575A
ASSEMBLY.
L67574A
4952177 4952170

33 34

 WARNING
 WARNING
ALWAYS LOWER
IMPLEMENT BEFORE
NO ETHER
LEAVING SEAT ELECTRICAL PREHEATER BUILT IN
L67553A

PERSONAL INJURY COULD RESULT

L67557A
4952179 11013034

35 36

 WARNING  WARNING
BRAKE SYSTEM OIL STORED UNDER HIGH BRAKE SYSTEM OIL STORED UNDER HIGH
PRESSURE, BEFORE SERVICING BRAKE SYSTEM PRESSURE, BEFORE SERVICING BRAKE SYSTEM
PARK MACHINE ON LEVEL SURFACE. LOWER ALL PARK MACHINE ON LEVEL SURFACE. LOWER ALL
IMPLEMENTS TO THE GROUND. SHUT ENGINE OFF. IMPLEMENTS TO THE GROUND. SHUT ENGINE OFF.
BLOCK WHEELS AND OPERATE PARKING BRAKE BLOCK WHEELS AND PUMP BRAKE PEDALS UNTIL
CONTROL UNTIL SYSTEM IS COMPLETELY SYSTEM IS COMPLETELY DISCHARGED.
DISCHARGED. TO SERVICE ACCUMULATOR, REFER TO SERVICE ACCUMULATOR, REFER TO SERVICE
L67573A

L67556A
TO SERVICE MANUAL. 4952320 MANUAL. 4952169

37 38

CALIFORNIA
11046865

Proposition 65 Warning
SPREADER BAR
Diesel engine exhaust and some of its L=2000 mm

constituents are known to the State of

California to cause cancer, birth
L67558A

defects, and other reproductive harm.

STEERING FRAME LOCK MUST BE DENOTES

39 CONNECTED AND SPREADER BAR TIE DOWN

L67571A

MUST BE USED WHEN LIFTING LOCATION

4952164

40
 Presentation
14 The USA Federal Clean Air Act

The USA Federal Clean Air Act

The Federal Clean Air Act Section 203 (a) (3) states that the re-
moval of air pollution control devices or the modification of a non-
road engine certified according to norms issued by EPA (Environ-
mental Protection Agency) to a non certified configuration is pro-
hibited.
The federal regulations which control the execution of the Clean
Air Act for non-road engines, 40 CFR (Code of Federal Regula-
tions) section 89.1003(a)(3)(i), states:

The following acts and the causing thereof are prohibited:

For a person to remove or render inoperative a device or ele-
ment of design installed on or in a non-road engine vehicle or
equipment in compliance with the regulations in this section
prior to its sale and delivery to the ultimate purchaser or
knowingly to remove or render inoperative such a device or
element of design after the sale and delivery to the ultimate
purchaser.

The law provides a penalty of up to $2,500 for each violation

Modifications such as recalibration of the fuel system so that the

engine will exceed the certified horsepower or certified torque is an
example of prohibited changes.

You must not make such modifications to a certified non-road en-

gine, certified according to norms issued by EPA, the result of
which would be an engine that does not match the engine config-
uration which is certified according to Federal Standards.

Customer support
Volvo Construction Equipment wishes to help assure that the
Emission Control System Warranty is properly administered. In the
event that you do not receive the warranty service to which you be-
lieve you are entitled under the Emission Control System Warran-
ty, you should contact the nearest Volvo Construction Equipment
Regional office for assistance.
 Presentation
The USA Federal Clean Air Act 15

Normal non-road engine use

The Maintenance Instructions are based on the assumption that
this conventional machine will be used as described in the Opera-
tor’s Instruction Manual and that specified fuel and lubrication oils
are used for its operation.

Non-road engine maintenance

This is a non-road engine of conventional design and any local
dealer can perform the required maintenance of emission control-
ling devices for non-road engines as defined in this manual.

The purchaser is strongly recommended by Volvo to follow the reg-

ular service instructions for the non-road engine under the heading
“Basic preventive maintenance”, which also include recommended
maintenance of engine emission control devices.

Volvo recommends that the owner should keep and preserve

records or receipts showing the performance of regular mainte-
nance in order to document that such maintenance has been car-
ried out. These records or receipts should be transferred to each
subsequent purchaser of the non-road engine.

Service performed by your local dealer

Your local dealer is best suited to give you good, dependable serv-
ice since he has trained service technicians and is equipped with
genuine original manufacturer´s parts and special tools and the lat-
est technical publications. Discuss your servicing and mainte-
nance requirements with your local dealer. He can tailor a
maintenance program for your needs.

For regular, scheduled service or maintenance, it is advisable to

contact your local dealer in advance to arrange for an appointment
to ensure availability of the correct equipment and service techni-
cian to work on your machine. In this way you will assist your local
dealer in reducing the time required to carry out the service of your
machine.

Preventive maintenance
If the non rod engine is to preserve the reliability and performance
regarding sound and emission levels as it had when supplied, it is
necessary to give it regular service, inspections and maintenance
and that its settings are adjusted at regular intervals.
 Presentation
16 The USA Federal Clean Air Act

Fuel system
Fuel recommendations
The fuel used must be clean, completely distilled, stable and non-
corrosive. Distillation series, cetane number and sulphur content
are the most important factors when selecting the fuel which will
give optimum combustion and the least possible wear.
The engine operating conditions and the ambient temperature in-
fluence the choice of fuel as regards its performance at low tem-
peratures, which is reflected in the cetane number.
If the machine is to operate at low temperatures, below 0 °C
(32 °F), a fuel of a lighter distillate or with a higher cetane number
is preferable. (Final boiling point max. 349 °C (660 °F) and a ce-
tane number of at least 45).
In order to avoid too great sedimentation and minimise the emis-
sions of sulphur dioxide, the sulphur content of the fuel must be as
low as possible. The diesel fuels recommended for use in Volvo
engines must meet the requirements according to ASTM D 975
No. ID (C-B) or No. 2D (T-T) and have a cetane number of no less
than 42 and a sulphur content not exceeding 0.5 percent by
weight.

Check for possible fuel leaks (while the engine is running at high
idle):
3 Make a visual check of connections and hose couplings.

Check the condition of fuel hoses with regard to:

3 Ageing
3 Cracks
3 Blisters
3 Scuffing

Check the condition of the fuel tank:

3 Drain condensation water.
3 Check for cracks.
3 Check for leaks.
3 Check mountings.

Check the turbocharger:

3 Make a visual check for any leaks of the turbocharger induction
hoses and exhaust pipe.
 Instrument panels
17

Instrument panels

WARNING!
Do not operate the machine until you are thoroughly famil-
iar with the position and function of the various instru-
ments and controls. Read through the Operator's Manual
thoroughly – Your safety is involved!

Keep the manual in the cab so that it always is at hand.

4 3 2

L67497A

Instrument panels
1 Right instrument panel (switches, rheostat, cigarette lighter,
hour recorder), see pages 18–23.
2 Front right instrument panel (switches, ignition switch, pro-
gramme selectors), see pages 24–25.
3 Centre instrument panel (central warning, warning and control
lamps, display unit, gauges), see pages 26–32.
4 Front left instrument panel (switches, keyboard for display
unit), see pages 33–34.
 Instrument panels
18 Right instrument panel

Right instrument panel

1 2 3 4 5 6 7

L67481B

1 Bucket positioner
Lower end of switch pressed in = Bucket positioner activated.
For further instructions, see page 56.

57164

2 Detent function, lifting / boom kick-out

Position 0 = Detent function not activated
Position 1 = Activation, detent function lifting to max. lift height
Position 2 = Activation, boom kick-out to set lift height

57160

3 Floating position
Lower end of switch pressed in = Floating position engaged when
the control lever for lifting/lowering has been moved forward to
floating position.
Switch in neutral position = Normal lifting/lowering function.
NOTE: With the switch in floating position, the lowering speed
will be lower.

4 Single-acting lifting function

(optional equipment)
Lower end of switch pressed in = Single-acting lifting function en-
gaged.
The attachment can now rise, e.g. if it encounters uneven ground,
but will return to the original position under its own weight.
 Instrument panels
Right instrument panel 19

5 Rear window wiper

Lower end of switch pressed in to position 1 = Intermittent position
connected.
Lower end of switch pressed in to position 2 = Normal position (the
wiper operates continuously).

57143B

6 Rear widow washer

Lower end of switch pressed in (spring return) = Rear window
washer connected.
Washer reservoir for windscreen and rear window, see page 126.

7 Secondary steering system

57143C
(optional equipment)

Operator instructions
If a fault should arise in the primary steering system, the red warn-
ing lamp lights up after which the amber control lamp on the centre
instrument panel also lights up to indicate that the secondary
steering pump has started.
57173
57180
NOTE: The secondary steering pump is engaged automatical-
ly, if the primary steering pressure is lost and if the travelling
speed is above 5 km/h (3 mph).
This should only be made use of as an emergency.

NOTE: If a fault has arisen in the primary steering system,

steer the machine to a suitable place, brake and stop the
machine. Do not use the machine again until the fault has
been rectified.

Function test
Before starting the engine and with the machine stationary, test the
function of the system as follows:
Turn the ignition key to the running position (position 1) and press
in the lower end of the switch. The secondary steering pump starts
and the amber control lamp on the centre instrument panel lights
up.
L57141
Turn the steering wheel and check that the steering works. Re-
lease the switch, which then returns to the "0" position. (If the red
warning lamp flashes in this situation, the secondary steering can-
not be restarted until the lamp has been extinguished).

NOTE: When testing the function of the secondary steering

pump, the pump must not be engaged for more than one
minute. There is a risk of overheating.
 Instrument panels
20 Right instrument panel

8 9

L67481C

10 11 12 13 14 15 16

8 Unassigned

9 Unassigned

10 Air conditioning (optional equipment)

Lower end of switch pressed in = Air conditioning connected.
For further instructions, see page 60.

L57139

11 Lights
Lower end of switch pressed in to position 1 = Parking and instru-
ment lights.
Lower end of switch pressed in to position 2 = Travelling lights
(high or low beams) turned on.
Switching high / low beam, see page 52.
A control lamp on the centre instrument panel indicates that the
L66356A high beams are connected.
 Instrument panels
Right instrument panel 21

12 Front working lights

Lower end of switch pressed in to position 1 = Working lights by
cab roof connected.
Lower end of switch pressed in to position 2 = Working lights by
cab roof and lower working lights (optional) connected.
Control lamp on the centre instrument panel indicates that the
working lights are connected.
L57155

13 Rear working lights

Lower end of switch pressed in to position 1 = Working lights in the
radiator casing connected.
Lower end of switch pressed in to position 2 = Working lights in the
radiator casing and by cab roof (optional) connected.
Control lamp on the centre instrument panel indicates that the
working lights are connected.
L57145
NOTE: Working lights should be off when travelling on public
roads.

14 Rotating warning beacon (optional equipment)

Lower end of switch pressed in = Warning beacon connected, see
also page 69.
Control lamp on the centre instrument panel indicates that the
warning beacon is connected.

L57150

15 Unassigned

16 Unassigned
 Instrument panels
22 Right instrument panel

19

L67481A

20 17 18 21

17 Function selector, Boom Suspension System

(optional equipment)
The switch has three positions. When starting the engine, the func-
tion reverts to the previously preselected position.
Regarding settings of Boom Suspension System in combination
with different attachments, see section "Operating techniques".
Upper end of switch pressed in = Deactivated Boom Suspen-
sion System.
L67478A
Switch in centre position = Gear-dependent Boom Suspen-
sion System.
– The control lamp for the Boom Suspension System lights and
on the display unit under the menu HYDRAULICS is shown
BSS – On or BSS – Off depending on whether the system is en-
gaged or disengaged (gear-dependent).
– The Boom Suspension System will be engaged in gear posi-
tions 2, 3 and 4.
– When changing down (kick-down) to gear position 1, the func-
tion will be disengaged.
Lower end of switch pressed in = Speed-dependent
Boom Suspension System (regardless of gear selector position).
– The control lamp for the Boom Suspension System lights and
on the display unit under the menu HYDRAULICS is shown
BSS – On or BSS – Off depending on whether the system is en-
gaged or disengaged (speed-dependent).
– If a certain travelling speed is exceeded, the BSS will be
engaged.
– Below a certain speed (approx. 5 km/h (3.1 mph) in forward
drive or approx. 2 km/h (1.2 mph) in neutral or in reverse drive)
the function will be disengaged.
 Instrument panels
Right instrument panel 23

18 Electrical control lever lockout (optional equip-

ment)
Applies to machines with a 4th hydraulic function.
The control lever lockout is used in order to avoid involuntary ac-
tuation of the control levers, for example when servicing or trans-
porting the machine.
Lower end of switch pressed in = Hydraulic function of control le-
vers disengaged.
L66838A

The switch is provided with a catch to prevent involuntary actua-

tion.

19 Rheostat, instrument lighting

This control is used for regulating the intensity of the instrument
lighting (gauges and control lamps).
L66301A Control turned to the right (clockwise) = Increased light intensity.
NOTE: Switches 11, 12 or 13 must be switched on.

20 Cigarette lighter
Voltage: 24 V

L66306A

21 Hour recorder
The gauge shows how many hours the engine has been running.
 Instrument panels
24 Front right instrument panel

Front right instrument panel

1 Preheating
The switch is used for connecting a preheating element in the inlet
manifold.
Lower end of switch pressed in at the same time as the ignition key
is turned to position 1 = Preheating connected.
The control lamp on the centre instrument panel lights.
Cold-starting instructions, see page 71.
L67275A

2 Transmission disengagement

WARNING!
The transmission disengage function must not be used
during transport operation.
L57142
Lower end of switch pressed in = The disengagement function is
activated and the power transmission will disengage when the
brakes are applied.
Upper end of switch pressed in = The transmission remains en-
gaged even when braking. It is recommended as the normal posi-
tion, as it provides smoother operation.

3 Automatic greasing (optional equipment)

For information about the system, see page 160.
Control lamp for signal codes is built into the switch. See page 163.
L66303A

4 Unassigned
 Instrument panels
Front right instrument panel 25

1 5 Ignition switch
2
R The ignition switch has five positions as shown in the figure.
3
0 Switched off (key-turn engine stop)
R Radio position
0
1 Running position
2 No function
L66305B
3 Starting position

6 Programme selector, gear-shifting programme

Mode Selector (APS II)

LIGHT (First position)

The machine shifts at low engine speed and low travelling speed.

LIGHT (Second position)

The machine shifts at slightly higher engine speed compared with
the first position.
NOTE: If the accelerator is depressed fully with the selector in
the "LIGHT" position, upshifting according to the "HEAVY"
position will take place.
The best utilisation is obtained if the accelerator is not depressed
fully, as the difference in upshifting speed between the LIGHT and
HEAVY modes will be more noticeable.
Both "LIGHT" modes provide better fuel economy and
smoother shifting during loading & carrying work.

HEAVY
The machine does not shift until higher engine and travelling
speeds have been reached.
Preferably used in cases where the machine changes gear when
operating uphill or when the rolling resistance is great.

MAN (Manual)
The machine starts and operates in the selected gear position. Up-
shifts and downshifts on the move are controlled manually.
For further gear shifting instructions, see page 72.
 Instrument panels
26 Centre instrument panel

Centre instrument panel

By taking action in time, it is possible to prevent serious damage
to the machine. Therefore, look now and then at the centre instru-
ment panel where the operator is provided with information should
something happen that requires his or her intervention. In order to
be able to check the function of instruments and controls, the cur-
rent must be turned on and the ignition switch be in position 1 (run-
ning position).
The information to the operator is provided in different ways de-
pending on the function involved:
– Amber central warning lamp flashes, if a function needs to be
kept under observation or whether a function becomes en-
gaged or disengaged. Information is shown on the display unit.
Action may be required depending on which function is in-
volved.
– Red central warning lamp flashes if abnormal operating val-
ues or faults occur. The warning lamp for the function lights up
at the same time as information is shown on the display unit.
Stop the machine immediately and take action.
For certain functions the buzzer sounds at the same time as the
red central warning lamp flashes, see page 28.
– The control lamps light when the respective functions are en-
gaged.
– The warning lamps light in case of malfunctions such as too
high or too low pressure, temperature or level.
– In addition to alarm texts the display unit also shows starting
sequence, operating information and settings, see page 35.
– The gauges show temperature or alternatively level. The warn-
ing lamp to the right of the gauge lights up if the temperature in
the respective system is too high or if the fuel level is too low.
 Instrument panels
Centre instrument panel 27

Central warning lamps

1 Central warning (amber)
2 Central warning (red)
Warning and control lamps
3 Battery charging (red)
4 Low engine oil pressure (red)
5 Low transmission oil pressure (red)
6 Low brake pressure or faulty brake pressure charging (red)
7 Working lights (amber)
8 Applied parking brake (red)
9 Low hydraulic oil level (red)
10 High axle oil temperature (red)
11 Faulty primary steering system (red)
12 High beams (blue)
13 Direction indicators (green)
14 Rotating warning beacon (amber)
15 Connected engine preheating (amber)
16 Engaged secondary steering (amber)
17 Engaged differential lock, front axle (amber)
18 Activated Boom Suspension System (green)
19 Activated lever steering (green)
20 Display unit
Gauges
21 Transmission oil temperature
22 Coolant temperature, engine
23 Fuel level
 Instrument panels
28 Centre instrument panel

1 Central warning (amber)

The lamp flashes when a function is engaged/disengaged or when
a function needs to be kept under observation (e.g. clogged filter).
Alarm text is shown on the display unit.
L66330A

2 Central warning (red)

The lamp flashes if abnormal operating values or faults arise. The
warning lamp for the function lights up at the same time and alarm
text is shown on the display unit.

Buzzer
L57167

The buzzer sounds and the red central warning lamp flashes if any
of the following faults occur:
– Serious engine fault
– Faulty primary steering system (low steering pressure)
– Computer failure
If directional gear (forward/reverse) is selected, the buzzer sounds
and the red central warning lamp flashes, if any of the following oc-
curs:
– Low engine oil pressure
– Low transmission oil pressure
– Low brake pressure
– Low hydraulic oil level
– Low coolant level
– High hydraulic oil temperature
– High transmission oil temperature
– High axle oil temperature, front and rear axles
– High coolant temperature
– High charge air temperature
– Faulty brake pressure charging
– Applied parking brake
– Overspeeding in selected gear

3 Battery charging
If the lamp lights when operating, the cause must be corrected as
the batteries otherwise may be damaged.

L57177
 Instrument panels
Centre instrument panel 29

4 Low oil pressure, engine

The lamp is alight if the lubricating oil pressure in the engine is too
low. As a precautionary measure the engine speed is, at the same
time, limited. Stop the engine immediately and rectify the fault.
L57166 The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.

5 Low transmission oil pressure

The lamp is alight if the oil pressure in the transmission is too low.
Stop and check the oil level or investigate any other cause of the
triggered warning. Rectify before continuing operation.
The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.

6 Low brake pressure

L57167C

WARNING!
The machine must not be operated until the fault has been
rectified and the control lamp has been extinguished.

The lamp is alight if the brake pressure is too low or if one brake
circuit does not work.
The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.

7 Working lights
The lamp lights when the working lights are switched on, see
page 21.

8 Applied parking brake

The lamp is alight when the parking brake is applied.
The buzzer sounds if a directional gear is selected and alarm text
57172 is shown on the display unit.
 Instrument panels
30 Centre instrument panel

9 Low hydraulic oil level

The lamp is alight when the oil level in the hydraulic tank is too low.
The buzzer sounds if a directional gear is selected and alarm text
57180b is shown on the display unit.

10 High axle oil temperature

The lamp will be alight when the oil temperature in the respective
axles is too high. Operate the machine in such a way that you do
not need to apply the brakes unnecessarily. The temperature in the
57175
axles will then drop to normal operating temperature.
The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.
NOTE: If the machine is equipped with additional axle oil cool-
ing, the axle will be cooled also when the machine is station-
ary with the engine running.

11 Primary steering system

57180 WARNING!
If the warning lamp lights up while operating, the machine
must not be operated until the fault has been rectified and
the warning lamp has been extinguished. Moving the
machine very slowly (below 5 km/h (3 mph)) to the nearest
suitable place where it can be parked and repaired, may be
carried out.

The lamp will light up if a fault arises in the primary steering system
(applies only to machines with a secondary steering)
For further instructions, see page 19.

12 High beams
The lamp lights when high beams are switched on, see page 52.

L66344A
 Instrument panels
Centre instrument panel 31

13 Direction indicator
The lamp flashes when the right or left direction indicators are
switched on, see page 52.
Uneven flashing pulses indicate a faulty bulb, which then should
57178
be replaced.

14 Rotating warning beacon

The lamp lights when the rotating warning beacon is switched on.
See page 69.

15 Preheating
The lamp lights when the preheating is connected.
After 10–50 seconds (the time depends on the coolant tempera-
ture) the preheating element will be automatically disconnected
57182
and the lamp extinguished.
The preheating element is automatically reconnected when start-
ing if required and if the lamp lights when the ignition key is turned
to position 1, see page 71.

16 Secondary steering
The lamp lights up when the secondary steering pump starts as a
consequence of a fault in the primary steering system, see page
57173
19.
NOTE: The lamp may also light up, without there being a fault
in the system, if a powerful steering movement is made at low
engine speed, or if the system needs “support”, for example
if the accelerator pedal is let up quickly at the same time as a
powerful steering movement is made. The pump will start
without the red warning lamp lighting up.

17 Differential lock, front axle

The lamp lights when the lock is engaged.
The foot switch for the differential lock is positioned on the floor to
L66345A the left of the steering wheel column.
 Instrument panels
32 Centre instrument panel

18 Boom Suspension System (BSS)

The lamp lights with a fixed light when the Boom Suspension Sys-
tem is activated.
57183

19 Lever steering (CDC)

The lamp is alight when the lever steering is activated. It is possi-
ble to steer the machine and select gears from the armrest to the
left of the operator's seat.
57179

NOTE: The ordinary gear selector control should be in neu-

tral.
For further instructions, see page 75.

20 Display unit
For description, see page 35.

21 Transmission oil temperature

22 If the gauge indicates into the red sector, the warning lamp to the
right of the gauge lights up. As a precautionary measure the en-
gine speed is, at the same time, limited. Stop the machine and in-
23 vestigate the cause.
The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.

22 Coolant temperature, engine

If the gauge indicates into the red sector, the warning lamp to the
right of the gauge lights up. As a precautionary measure the en-
gine speed is, at the same time, limited.
L68244A
Run the engine at low idling for a few minutes. If the gauge contin-
21 ues to indicate within the red sector, stop the engine and investi-
gate the cause.
The buzzer sounds if a directional gear is selected and alarm text
is shown on the display unit.

23 Fuel Level
When the gauge pointer indicates that the tank is empty, the warn-
ing lamp to the right of the gauge lights up. The amount of spare
fuel left at this point is estimated to last one hour of normal opera-
tion. The machine should be refuelled to avoid air entering the sys-
tem.
If the tank has been run dry, see pages 121 or 122.
Capacities, see pages 169 and 184.
 Instrument panels
Front left instrument panel 33

Front left instrument panel

5 6 1 2 3 4

P
L66310A

1 Raised pressure – attachment locking

(optional equipment)
Is used if a greater hydraulic pressure is required when connecting
or disconnecting an attachment.
Lower end of switch pressed in = Raised pressure on locking pins
when changing attachments.
The switch has a spring return function and therefore always re-
L57138 turns to neutral. It is also provided with a catch to prevent involun-
tary actuation.

2 Separate attachment locking

(optional equipment)
This equipment makes it possible for the operator to connect and
disconnect attachments from the operator's seat.
Lower end of switch pressed in = Unlocked position.
Upper end of switch pressed in = Locked position.
L57149 The switch is provided with a catch to prevent involuntary actua-
tion.
Attaching and disconnecting attachments, see page 87.
WARNING NOTE: When the switch is switched on, it is possible to oper-
ate the tilting and lifting functions simultaneously in order to
align the attachment.
L67523A

11 111 506

WARNING!
Before using the machine, check that the attachment is
securely connected and locked to the attachment bracket
by pressing the front end of the attachment against the
ground.
 Instrument panels
34 Front left instrument panel

3 Hazard flashers
Lower end of switch pressed in = All direction indicators on the ma-
chine will flash in time with the lamp in the switch together with the
control lamp for direction indicators. The hazard flashers can be
used even if the ignition switch key has not been turned on.

L57147

4 Unassigned

5 Parking brake
The switch is provided with a catch to prevent involuntary actua-
tion.
For the function of the parking brake, see page 50.

L66339A

6 Keyboard for display unit

For information about the keyboard and the display unit, see the
next few pages.

AUX SETUP

ESC SELECT

L66312A
 Instrument panels
Display unit 35

Display unit
The display unit, which is positioned on the centre instrument pan-
el, shows starting sequence, current operating information and
alarm texts. With the aid of the keyboard on the front left instru-
ment panel the operator may also have information about the ma-
chine status and make settings.

Initial display
When the ignition key is turned to position 1, a test programme will
begin to run to verify the system. This starting sequence takes 4–
5 seconds and its progress is shown by the way of black squares
increasing in number from one to seven. During the first part the
control lamps will light up and the gauges will indicate (at twelve
L63203A
o'clock).
NOTE: If the operator turns the ignition key to position 3 (starting
position) immediately, without waiting for the starting sequence to
run, the alarm text "Transmission Oil Level Not Checked" will be
shown, provided a gear has been selected.

Operating information
After the initial display an "Operating Information" screen will be
shown including current information, provided that this screen was
displayed when the current was last switched off.
xxxx rpm If another screen was displayed when the current was last
ppp: yy
o
VV WWW
switched off, that screen will be displayed if the travelling speed is
below 20 km/h (12.4 mph). Press ESC to return to the Operating
zz:zz ttt Information screen.
L67494A

Engine speed / Er (non available information, e.g.

X computer failure)
P Active gear selector control, CDC/F/R/Er

Selected gear
y N/F1/F2/F3/F4/R1/R2/R3/R4/Er
Clock
z 24h/am/pm
Temperature
t °C/°F
v Travel speed /Er

w km/h/mph
 Instrument panels
36 Display unit

Keyboard for the display unit

With the aid of the keyboard the operator may have information
about the machine status and make settings.
Changing display screen is only possible if the speed is below 20
km/h (12.4 mph).

AUX SETUP

ESC SELECT

L63103B

ENGINE
TRANSMISSION
HYDRAULIC SYSTEM
Function key, direct selection
AXLES
ELECTRICAL SYS-
TEM
AUX

SETUP Is used for carrying out settings

ARROW UP
Is used for browsing through the menus of the function groups and the settings
ARROW DOWN
SELECT Used for selecting and confirming the selected setup

With the ESC key the display is always returned to the "Operating Information"
ESC screen regardless of the current position within the menus.
 Instrument panels
Display unit 37

Machine information
Information about the machine status is obtainable by pressing the
respective function on the keyboard.
Each function group consists of one or more display screens (men-
us).
If there are more than one screen for each function group, an ar-
row pointing downward will be displayed in the bottom, right cor-
ner. To browse within the function group, press arrow down or
arrow up.
To revert to the "Operating Information" screen, press the ESC
key.

ENGINE
Temp. xxxx xx
Rev. yyyy rpm
Pressure zzzzzz

x = Coolant temperature /Er

Unit °C / °F (temperature is shown down to 0 °C (32 °F) and be-
low 0 °C (32 °F) <0 / <32 is shown
y = Engine speed/Er
z = Engine oil pressure
Normal/Low/Er

ENGINE
Oil Level xxxxxx
Fluid Level yyyyyy

x = Engine Oil Level: Normal/Low/Er

y = Coolant Level: Normal/Low/Er
 Instrument panels
38 Display unit

TRANSMISSION
Lever xx Gear yy
Temp. zzz zz
Pressure vvvvvv

x = Gear selector position

N/F1/F2/F3/FA/R1/R2/R3/RA/Er
y = Selected gear
N/F1/F2/F3/F4/R1/R2/R3/R4/Er
z = Transmission oil temperature /Er
Unit °C / °F (temperature is shown down to 0 °C (32 °F)
and below 0 °C (32 °F) <0 / <32 is shown
v = Transmission oil pressure
Normal/Low/Er

TRANSMISSION
Level xxxxxx
Filter yyyyyy

x = Transmission oil level

y = Transmission oil filter: Normal/Clogged/Er

TRANSMISSION
APS II xxxxxx
Trans.diseng. yyy

x = APS II (mode selector)

Light 1/ Light 2/ Normal/ Heavy/ Man/ Er / - .
v = Transmission disengagement
On: Activated Off: Not activated
 Instrument panels
Display unit 39

HYDRAULICS
Level xxxxxx
Temp. yyy
BSS vvvvvv

x = Level hydraulic tank

Normal/Low/Er
y = Temperature hydraulic oil
Normal/High/Er
v = Boom Suspension System On: Engaged Off: Disengaged

AXLES/BRAKES
Br.Pressure xxxxxx
Temp. Front yyyyyy
Temp. Rear zzzzzz

x = Brake pressure
Normal/Low/Er
y = Temperature front axle
Normal/High/Er
z = Temperature rear axle
Normal/High/Er

BRAKE TEST
Travelling speed xx yyy
zzz m/s2 vv.v bar
See Instructions

x = Machine travelling speed

yy (km/h / mph)
z = Recorded retardation
zz (m/s2)
v = Output brake pressure, front
vv (bar)
 Instrument panels
40 Display unit

ELECTRICAL SYSTEM

Voltage xx.x V

x = Present voltage in the electrical system

xx (V)

DATE / TIME

xxxx-xx-xx yy:yy

x = Display of date according to selection under the SETUP menu.

y = Display of time according to selection under the SETUP menu,
24h or alternatively am/pm

INFORMATION I
Wheel Loader xxx x
Tyres yyyy

x = Machine type L50X, L70X, a.s.o. (according to setup via serv-

ice display unit)
y = Tyre size (according to setup via service display unit)

INFORMATION II
Time xx:xx,xx
Distance yy.y yy
Cycles zzz Cl = Sel.

x = Machine time (hours, minutes, seconds)

y = Travelling distance yy.y in km / mile
z = Number of F/R turns / 2 (3 characters)
Cl = Sel. = Zero setting (Also sets fuel consumption to zero)
 Instrument panels
Display unit 41

FUEL CONSUMPTION
Inst. xxxx x/h
Avg. yyyy y/h
Total zzz z

x = Current fuel consumption in litres/hour

y = Average consumption per hour after setting to zero
z = Total consumption after setting to zero
The setting to zero of the fuel consumption takes place at the same
time as setting to zero is carried out in the previous menu INFOR-
MATION II.

NEXT SERVICE
Resid. Time xxxx h
Interval yyyy h
Acknowledge: Sel.

x = Residual time to next service, xxxx h

y = Interval 250/500/1000/2000
When there are eight hours left until the next service SERVICE
INFO Time For Service will be shown on the display unit.
Acknowledge after completed service with SELECT (press for 3–
5 seconds) this also applies when changing engine oil.

NEXT SERVICE
Resid. Time
Engine Oil Change

For normal operating conditions the interval between oil changes

is 500 hours. Each black rectangle represents 50 hours. Counting
down takes place from right to left in steps of 50 hours.
 Instrument panels
42 Display unit

Settings via the keyboard

Setting up language, units, machine hours and date/time is done
as shown below:

Setup, Language and Units

– Press SETUP.
– Press SELECT.
– Browse with ARROW UP/DOWN to the required language.
– Confirm with SELECT.
The display will now automatically change to the line for selecting
units.
– Browse with ARROW DOWN to the required unit.
– Confirm with SELECT.

SETUP
Language
Units

x xx x xx xxx

– Press ESC to return to the Operating Information screen.

Setup, Machine Hours

(only to be done after replacing the V-ECU)
– Press SETUP.
IMPORTANT! Setting up machine – Press ARROW DOWN for the menu "Machine hours".
hours should only be done after re- – Press SELECT.
placing the V-ECU. This is in order to – Browse with ARROW UP/DOWN to the correct digit.
restore the total number of machine
hours for the machine. – Confirm each digit with SELECT.

MACHINE HOURS

Hours xxxxx

– Press ESC to return to the Operating Information screen.

 Instrument panels
Display unit 43

Setup, Date / Time

– Press SETUP.
– Press ARROW DOWN for the menu "Date / Time".
– Press SELECT.
– Browse with ARROW UP/DOWN to another alternative.
– Confirm the alternative and each digit with SELECT.
The following display alternatives are available:
1 year - month - day - 24 h
2 year - month - day - am/pm
3 month - day - year - 24 h
4 month - day - year - am/pm
5 day - month - year - 24 h
6 day - month - year - am/pm

DATE / TIME

yyyy-mm-dd yyyy-mm-dd yy:yy

Alt. x

– Press ESC to return to the Operating Information screen.

 Instrument panels
44 Alarm texts

Alarm texts
The information to the operator is provided on the display unit in
the form of alarm texts, which are divided into four classes: Warn-
ing, Info, Error and Service Info, see below. For all classes applies
that at speeds above 20 km/h (12.4 mph) the alarm text is shown
for two seconds and is then alternated with the previous screen
which is shown for three seconds. This alternate showing of the
two screens continues as long as the error situation remains, or al-
ternatively until the alarm is shown a certain number of times.

WARNING
– Is shown regardless of which screen was shown previously.
– Alarm text will be shown for two seconds alternately with the
previous screen which will be shown for three seconds (this will
be repeated as long as the error situation remains).
– Red central warning lamp will be flashing.
– Rectify or contact authorised dealer workshop for information.

INFO
– Is shown regardless of which screen was shown previously.
– Alarm text will be shown for two seconds alternately with the
previous screen which will be shown for three seconds (this will
be repeated three times).
– Amber central warning lamp will be flashing.
– Rectify or contact authorised dealer workshop for information.
The alarm will be repeated at the next start, if it still is "active".

ERROR
– Is shown regardless of which screen was shown previously.
– Alarm text will be shown for two seconds alternately with the
previous screen which will be shown for three seconds (this will
be repeated as long as the error situation remains).
– Amber central warning lamp will be flashing.
– Contact authorised dealer workshop for information.

SERVICE INFO
– Is shown regardless of which screen was shown previously.
– Alarm text will be shown for two seconds alternately with the
previous screen which will be shown for three seconds. Is re-
peated until acknowledgement has been carried out via the
menu NEXT SERVICE or the alarm has been brought to an end
in any other way specified for the function (for example replac-
ing filter).
– Amber central warning lamp will be flashing.
– Rectify or contact authorised dealer workshop for information.
 Instrument panels
Alarm texts 45

Engine Transmission

Min. F/R
INFO * INFO
Engine Oil Level Deactivated

Clogged
Clogged
INFO INFO Transmission
Engine Air Filter
Oil Filter

No Engagement
High Temp.
INFO INFO F/R
Engine Starter Motor
CDC Active

Transmission
High Temp.
INFO INFO Oil Level
Engine Oil
Not Checked

Min.
High Temp.
WARNING INFO *** Transmission
Charge Air
Oil Level

Slip in
Low
WARNING INFO Transmission
Engine Oil Pressure
Clutches

High Slip in
WARNING Engine Coolant WARNING Transmission
Temperature Clutches

Low Low
WARNING ** Engine WARNING Transmission
Coolant Level Oil Pressure

High
Electrical system WARNING Transmission
Oil Temp.

High Overspeeding
INFO WARNING
Voltage On Selected Gear

Low
INFO
Voltage

*) A level check takes place when starting the engine, if the engine has remained off for more that 10 minutes.
**) The level is checked continuously during operation.
***) A level check only takes place once the following conditions have been met:
Gear selector control = in neutral
Engine speed < 1000 rpm
Transm. oil temp. > 55 °C
The machine is stationary > 10 s
If the gear selector control is moved to forward or reverse within 10 seconds, there will be a message that the
level check has been interrupted.
 Instrument panels
46 Alarm texts

Axles Miscellaneous

Increasing Low
INFO INFO **
Front Axle Oil Temp. Washer Fluid Level

SERVICE
Increasing Time For Service
INFO INFO
Rear Axle Oil Temp.

SERVICE
High *** Time For
WARNING INFO
Front Axle Oil Temp. Engine Oil Change

High Turn off Engine

WARNING STOP! ****
Rear Axle Oil Temp. XXXX YYY

Hydraulics ***** Check/Clean

INFO
Condenser

INFO
Min. Engine
Hydraulic Oil Level

High Monitoring
WARNING ERROR
Hydraulic Oil Temp. Engine Oil Level

Low Monitoring
WARNING * Steering System ERROR Engine
Oil Pressure Oil Pressure

Low Monitoring
WARNING ERROR
Brake Pressure Engine Oil Temp.

Applied Monitoring
WARNING ERROR
Parking Brake Fuel Level

Brake Charging Monitoring

WARNING ERROR
Failure Coolant Level

Monitoring
WARNING Low
ERROR Engine
Hydraulic Oil Level
Coolant Temp.

*) Applies only to machines with secondary steering installed

**) The level is checked continuously during operation.
***) Is shown on the display screen if the oil needs to be changed after 250 hours (500 hours is normal). If the
alarm is repeated again before the end of the 500 hour interval, it is recommended that the interval is reset to
250 hours by an authorised workshop. Acknowledgement of the alarm is done by pressing SELECT in the menu
NEXT SERVICE.
****) XXXX = Description of fault PPID, PID/SID
YYY = Numerical value 1–999
IMPORTANT! Make a note of any displayed error code and contact an authorised workshop.
*****) Only applies to machines equipped with air conditioning.
 Instrument panels
Alarm texts 47

Engine Transmission

Monitoring
Monitoring
ERROR Coolant Outlet ERROR
Turbine Revolutions
Temp.

Monitoring Monitoring
ERROR Engine ERROR Transmission
Air Filter Oil Level

Monitoring Monitoring
ERROR Radiator Fan ERROR Transmission
Revolutions Oil Pressure

Monitoring
Monitoring
ERROR ERROR Transmission
Charge Air Temp.
Oil Temp.

Monitoring
ERROR Preheating Relay ERROR Transmission
Oil Filter

Radiator Fan Monitoring

ERROR ERROR
Control Travel speed

Accelerator Pedal
ERROR ERROR APS II switch
No Back-up Function

Accelerator Pedal
ERROR Reduced Function ERROR Gear Selector
Activated

Gear-shifting
ERROR Hand Throttle ERROR
Solenoids

Monitoring Gear Selector

ERROR ERROR
Engine Revolutions F/R

E-ECU Gear Selector

ERROR * ERROR
XXXX YYY CDC

Electrical system

Relay
ERROR
Intermittent Wiper

*) XXXX = Description of fault PPID, PID/SID

YYY = Numerical value 1–999
IMPORTANT! Make a note of any displayed error code and contact an authorised workshop.
 Instrument panels
48 Alarm texts

Axles

Monitoring
ERROR
Axle Oil Temp.

Differential Lock
ERROR

Hydraulics

Monitoring
ERROR Steering System
Oil Pressure

Monitoring
ERROR
Hydraulic Oil Temp.

Parking Brake
ERROR
Circuit

Monitoring
ERROR
Output Brake Pressure

Secondary
ERROR
Steering Relay

ERROR Parking Brake

Lever Steering
ERROR
CDC

Relay
ERROR
BSS

Miscellaneous

Reduced
ATTENTION! *
Computer Function

Computer Failure
STOP
** STOP THE VEHICLE

*) Computer malfunction between the ECUs. The machine can only be operated in first and second gear. Only
Operating Information and Alarms are available on the display unit.
**) Contact an authorised workshop for information.
 Other controls
Controls 49

Other controls
Controls
4 5 6 7
3 8
9
2 10
11
1 12

13

14

L67498C

1 Lever steering, CDC (optional equipment)

2 Parking Brake
3 Gear selector control
4 Brake pedal
5 Differential lock
6 Steering wheel adjustment (optional equipment)
7 Brake pedal
8 Headlight dipper / windscreen washer, direction indicators /
horn, windscreen wiper
9 Accelerator pedal
10 Mode selector
11 Hand-throttle control (optional equipment)
12 Control lever carrier: working hydraulics, kick-down, horn, en-
gine retarding, control lever lockout, Forward/Reverse shifting,
Forward/Reverse activation
13 Heating and ventilation
14 Arm rest
 Other controls
50 Controls

1 Lever steering, CDC (optional equipment)

3 The equipment consists of a folding arm rest where three oper-
ating functions are collected: steering, forward/reverse and
kick-down.
3 The functions are activated by folding down the arm rest and
57179

pressing the activating button.

Control lamp, CDC
3 When the system is activated, a control lamp on the centre in-
strument panel is on.
For further instructions, see page 75.

2 Parking brake
3 The control lamp lights on the centre instrument panel when the
parking brake is applied. If the parking brake is applied when a
directional gear is selected, the red central warning lamp flash-
57172
es and the buzzer sounds.
Control lamp,
3 The catch on the switch prevents the parking brake from being
parking brake
released accidentally

Application
– Move the gear selector to neutral.
– Press in the lower end of the switch. The machine must be
completely stationary before application.
– Turn the ignition key to the "0" position.
3 If the engine is turned off without the parking brake having first
been applied, this takes place automatically.

L66339A
Releasing
– Slide down the catch and press in the upper end of the switch.

Releasing (if the parking brake has been applied automatical-

ly):
– Press in the lower end of the switch.
– Then slide down the catch and press in the upper end of the
switch.
NOTE! If a directional gear has been engaged and the engine
speed increased to 1600 rpm the parking brake will be re-
leased (safety function). This way of releasing the brake must
not be used instead of releasing it with the aid of the switch.
 Other controls
Controls 51

3 Gear selector control

3 Shifting between the different speed gears is done by turning
the control.
NOTE! Never leave the machine with the gear selector in for-
ward or reverse, while the engine is running.
For further instructions on gear shifting, see page 72.
Direction gear, F-N-R
Selector in position F = Operating forward
Selector in position N = Neutral
Selector in position R = Operating rearward
L66350A
Kick-down button
For instructions, see page 74.

4 Brake pedal

5 Differential lock
3 The differential lock only affects the front axle.
3 It is engaged by depressing the foot switch and it remains en-
gaged as long as the foot switch is kept depressed.
L66345A
3 The control lamp on the centre instrument panel is alight when
the lock is engaged.
IMPORTANT! The differential lock may only be used when
operating on slippery ground.
3 When operating on firm ground, particularly when turning, the
lock must be disengaged.
3 If there is danger of getting stuck, engage the differential lock
before the machine has got stuck.
3 If the machine has become stuck and one of the wheels is slip-
ping, the wheel must be stopped before engaging the differen-
tial lock. Otherwise the drive axle system may be damaged.

6 Steering wheel adjustment (optional equip-

ment)
The control is positioned to the right under the steering wheel.
L61710A
Control downward = Adjustment of steering wheel inclination
Control upward = Adjustment of height

7 Brake pedal
 Other controls
52 Controls

8 Headlight dipper / windscreen washer

Away from steering wheel = High beams
Neutral position = Low beams
Towards steering wheel = Windscreen washer
93A

Direction indicator control / horn

Control forward = Left direction indicators
Control rearward = Right direction indicators
Button pressed in = Horn

Windscreen wiper
Position J = Intermittent wiper
Position 0 = Neutral position
Positions I and II = Windscreen wiper (two speeds)

9 Accelerator pedal
The accelerator position is transferred electrically.

10 Mode selector
See page 72.

11 Hand-throttle control (optional equipment)

The accelerator position is transferred electrically.
3 The control is positioned by the front right instrument panel.
3 The accelerator position is altered by turning the control. Turn-
ing clockwise increases the speed.
r / min
3 Depending on previous adjustment, the control may first have
to be turned counter-clockwise and then clockwise in order to
set the speed.
L67480A

3 Disengagement takes place when actuating the accelerator

pedal or the brake pedal.
3 When starting the engine, the hand-throttle is disengaged, re-
gardless of previous setting.
 Other controls
Controls 53

2 1 5 6
D 7

C C 8

B B 4 3 2 1 F
N
A A R

9
L67317A

2 1
F
C Tilting forward D Floating position R

C Lowering position 10
B Neutral position
A Tilting rearward B Neutral position L67486E

A Lifting position

12 Control lever carrier and control functions

Lever (1) for the lifting function has four positions: lifting,
neutral, lowering and floating.
Detent function lifting / boom kick-out
Activation and selection of detent function lifting or alternatively
boom kick-out is done with the switch. Thereafter the control lever
is moved to the max. lifting position.
Detent function lifting = the control lever remains in the lifting
position even after the lifting arms have reached the max. lifting
position, after which the control lever has to be moved back to
neutral by hand.
Boom kick-out = the control lever remains in the lifting position
until the lifting arms have reached a predetermined height.
Thereafter it returns to neutral automatically.
Detent function floating position
Floating position is activated with the switch. Then the control lever
is moved forward to floating position.

Tilting lever (2) has three positions: rearward, neutral and for-
ward.
Detent function tilting (bucket positioner)
Activation of bucket positioner, is done with the switch. Thereafter
the control lever is moved to max. rearward tilting position.
When the rearward movement of the attachment reaches a prede-
termined position, the control lever returns to neutral automatically.
Control lever (3) for the 3rd hydraulic function (optional
equipment)
3 Double-acting hydraulic outlets, are used if the machine, for ex-
ample, is equipped with a timber grapple.

Control lever (4) for the 4th hydraulic function (optional

equipment)
3 Double-acting hydraulic outlets, are used, for example, for a
further function in the timber grapple.
 Other controls
54 Controls

Kick-down (5)
3 The function can be selected from the control lever carrier, the
gear selector control (see page 74) and from the lever steering
(optional equipment), see page 75.

Horn (6)

Engine retarding (7)

3 Is used to obtain an immediate downshift when operating
downhill, or to prevent undesired upshifting. See page 75.

Directional gear F-N-R (8)

3 To be able to use the Forward/Reverse function on the control
lever carrier, the activating button (10) must first be depressed.
After activation F/R is shown: in front of the selected directional
gear on the display unit on the Operating Information screen
Switch in the forward position = Operating forward
Switch in centre position = Neutral
Switch in rearward position = Operating in reverse
3 If the ordinary gear selector control by the steering wheel is
moved from neutral, while operating with the F/R switch, the
gear selector at the steering wheel will over-ride the switch.
3 A new activation of the system requires that the activating but-
ton (10) is pressed again.

Control lever lockout (9)

3 Locks the control levers in neutral. The control lever lockout is
used in order to avoid involuntary actuation of the control le-
vers, for example when servicing or transporting the machine.
NOTE! On machines with a 4th hydraulic function, the control
lever lockout is electrical. The control lever lockout is en-
gaged with a switch on the right instrument panel so that the
L66838A hydraulic function of the control levers is disengaged.
Switch, control lever lockout
Activating directional gear (10)
NOTE! The ordinary gear selector control by the steering
wheel and the switch on the control lever carrier must, when
activating, be in neutral. The lever steering (optional equip-
ment) must not be activated.
3 If the ordinary gear selector control is actuated, the gear-shift-
ing function at the control lever carrier is lost and the selection
made with the ordinary gear selector control applies.
 Other controls
Controls 55

1 13 Controls, heating and ventilation

4
Settings, see page 60.
2 1 0 3
3
14 Arm rest
The arm rests for control lever carrier and lever steering (optional
2 equipment) can be adjusted to give the operator an as comfortable
operating position as possible, see page 59.

L68295A

1 Fan control
2 Temperature control
3 Recirculation control
 Other controls
56 Boom kick-out and bucket positioner

Boom kick-out and bucket posi-

tioner
Boom kick-out and bucket positioner causes the bucket and the
lifting arms automatically to stop in predetermined positions. This
will result in shorter cycle times and reduced wear. The adjust-
ments of the required position for the bucket or the required height
57164 57160
when lifting are done according to the instructions given below.
Bucket positioner Boom kick-out
Operation
3 The automatic functions boom kick-out and bucket positioner
are switched on with the respective switches.
3 Tilt the attachment forward and lower the lifting arms.
3 When thereafter either of the control levers is moved to maxi-
mum lifting or tilting rearwards (with switched on switches) the
lever is kept in the detent position and the movement continues
to a predetermined position, whereafter the respective lever re-
turns to neutral.

Adjusting tilting rearwards

1 Move the bucket to the required position.
2 Stop the engine, but leave the ignition key in running position.
3 Slacken the nuts for the bracket and move the sensor to its
rear position.
4 Switch on the switch for the bucket positioner.
L67077A 5 Move the tilting lever to the rear detent position.
Sensor, bucket positioner 6 Displace the sensor toward the rod until the light emitting diode
lights up.
7 Tighten the nuts for the bracket.

Adjusting lift height

1 Raise the lifting arms to the required position.
2 Stop the engine, but leave the ignition key in running position.
3 Slacken the nut for the bracket and move the sensor to its rear
position.
4 Switch on the switch for the boom kick-out.
L67078A
5 Move the lifting lever to the rear detent position.
Sensor, boom kick-out
6 Displace the sensor forward until the lifting lever returns to
neutral.
7 Tighten the nut for the bracket.

IMPORTANT! The distance (A) between the sensors and the

actuating part of the machine should be 3–5 mm (0.12–
L41037A
0.20 in). See the adjacent figure.
 Other controls
Operator comfort 57

Operator comfort
Operator seat
The operator seat meets the criteria of EN ISO 7096:2000. Briefly,
this means that the seat is designed to minimize whole-body vibra-
tions during machine operation, in the best possible way. The size
of the vibrations depends on different factors, many of which are
not related to the construction of the machine, such as ground con-
ditions, speed and operating techniques. Note the following:
– Adjust the seat according to the operator weight and height
– Keep the ground on the work site in good condition
– Choose the correct operating technique and speed for the ex-
isting circumstances.
Correctly adjusted operator seat increases operator comfort and
safety. Incorrectly adjusted seat may lead to injuries. The adjust-
ments that should be made are:
A Back-rest inclination
B Lumbar support
C Inclination and raising/lowering seat
D Operator weight
E Longitudinal (leg room)
(The controls for the different adjustments may vary depending on
seat model.)
NOTE! Do not adjust the seat while the machine is moving.

Mechanical seat
180
0 90 2
70
14

20 110

KG
50
100

260

LBS
0

4 30

C D

B
F
E
KG

LBS
KG

LBS
KG

KG LB S

LBS

L66340A
A L66341A

A Back-rest inclination
Pull the handle upward and adjust to the required inclination.
B Lumbar support
Turn the knob to the required setting (hard/soft).
C Height and inclination
Pull the handles upward and lift or downward and lower the rear
or front end of the seat.
Never adjust the height of the seat with the weight adjust-
ing wheel
D Adjusting for weight
Adjust the seat according to the relevant weight with the adjust-
ing wheel. While sitting in the seat try to adjust so that the
upward and downward movement ranges are equally distrib-
uted.
Should not be used for adjusting height.
E Longitudinal (leg room)
Pull the bar upward and push the seat (forward/rearward).
F Switch for electrically heated (optional equipment)
 Other controls
58 Operator comfort

Air-suspended seat
The adjustments are carried out in the same way as for the me-
chanical seat, except for lumbar support and weight adjustments.
B Adjusting lumbar support
Using the buttons it is possible to fill and empty the upper and
lower lumbar supports separately as required.
D Adjusting for weight
By pressing the button marked + for filling and – for emptying,
L66529A
the seat suspension can be adjusted according to the relevant
D B operator weight.
While sitting in the seat try to adjust so that the upward and
downward movement ranges are equally distributed.
Should not be used for adjusting height.

Lap type seat belt, checking and mainte-

nance
3 Replace the belt if it is worn, damaged or if the machine has
been involved in an accident where the belt had to take some
strain.

3 Changes to the belt or its mountings must never be made.

3 The seat belt is intended for one grown up person only.

3 Keep the belt rolled-up when not in use.

3 Change the belt every third year regardless of its condition.

3 When washing, use a mild soap solution and allow the belt to
dry while it is fully pulled out, before rolling it up. Make sure the
belt is installed in a correct way.
 Other controls
Operator comfort 59

Arm rest
The arm rests for control lever carrier and lever steering (optional
equipment) and the control lever carrier can be adjusted to give the
operator an as comfortable operating position as possible.

Adjusting arm rest for control lever carrier

B
A Up/down
A
L63173A
1 Loosen the handle and adjust to the required height.
2 Tighten the handle.
B Angle
C
1 Loosen the handle and adjust to the required angle.
2 Tighten the handle.

Adjusting control lever carrier

C Forward/rearward
1 Loosen the handle and adjust to the required angle.
2 Tighten the handle.

D Adjusting arm rest for lever steering

D Forward/rearward and sideways
E 1 Loosen the handle and adjust forward/rearward and sideways
L68284A
to required position.
2 Tighten the handle.
E Angle
1 Loosen the handle and adjust to the required angle.
2 Tighten the handle.

Steering wheel adjustment

(optional equipment)
The steering wheel should be adjusted so that the operating posi-
L61710A
tion becomes as comfortable as possible.
Control downward = Adjustment of steering wheel inclination
Control upward = Adjustment of height
 Other controls
60 Operator comfort

Climate control system

5 5

2-3

L63061C

4
1 1 Fan control
2 1 0 3 Position 0 = Turned off
3

Position 4 = Maximum speed

2 Temperature control
2
Control forward (blue) = Cold
Control rearward (red) = Warm
L68295A

3 Recirculation control
Control forward = Maximum recirculation
Control rearward = Minimum recirculation

4 Switch, air conditioning

Lower end of switch pressed in = Air conditioning engaged (the fan
starts automatically on the lowest speed if its control is in 0-posi-
L57139
tion).
Air conditioning If the pressure in the system becomes too high (e.g. if the con-
denser is clogged up) or too low, the air conditioning will cut out.
Investigate and rectify the cause of the altered pressure before re-
starting the function, see page 133.
B
A
5 Ventilation nozzles
Open ventilation nozzles to obtain the best possible ventilation.

C L68569A
A Open
B Closed
C Air flow direction
 Other controls
Operator comfort 61

Adjusting heating and ventilation

The instructions below are basic recommendations. Each operator
should experiment to achieve the best possible working environ-
ment in the cab, i.e. the right temperature without a draught.

4 How to achieve ...

2 1 0
3

... max. warmth:

3 All nozzles fully open.
3 Temperature control (2) at red.
3 Recirculation control (3) forward.
3 Fan control (1) at max.
L68239A

In case of misting, see "... demisting all windows".

4 ... max. cooling:

2 1 0
3

3 All nozzles fully open.

3 Temperature control (2) at blue.
3 Recirculation control (3) rearwards.
3 Fan control (1) at max.

L68240A

... comfortable working temperature:

3 All nozzles fully open.
3 Settle the temperature with temperature control (2) and fan
control (1) until the required temperature is achieved.

... demisting all windows:

4
2 1 0 3 Front nozzles directed towards front side windows.
3

3 Floor nozzles under instrument panel closed.

3 Rear nozzles directed toward the rear window / side window.
3 Temperature control (2) at red.
3 Recirculation control (3) rearwards.
L68241A
3 Fan control (1) at max.

Provide for good ventilation

Do not operate the machine for long periods without ventila-
tion or with the cab fully closed without having the fan turned
on.
Poorly ventilated air can cause tiredness (lack of oxygen).
 Other controls
62 Operator comfort

Adjusting heating and ventilation with air condi-

tioning
4
2 1 0
3

How to achieve ...

... rapid cooling:
3 All nozzles fully open.
3 Temperature control (2) at blue.
L68242A
3 Recirculation control (3) forward.
3 Fan control (1) at max. speed.
3 Switch (4) depressed, i.e. the air conditioning switched on.

... demisting all windows:

3 Front nozzles directed towards front side windows.
3 Floor nozzles under instrument panel closed.
4
2 1 0 3 Rear nozzles directed toward the rear window / side window.
3

3 Temperature control (2) at blue.

3 Recirculation control (3) at rearwards.
3 Fan control (1) at max. speed.
3 Switch (4) pressed down (the air conditioning switched on).
L68240B

When the temperature has dropped sufficiently:

3 Fan control (1) set to 1 or 2.

NOTE! The temperature is regulated with the fan control and

the temperature control in order to obtain a pleasant temper-
ature.

2 Window catch
The right side window, which also is the emergency exit from the
160 cab, can be opened to two positions:

Position 1 (open approx. 10°)

10 3 Lift up locking catch (A), open the window and secure it with
stop (B).
A
1 Position 2 (fully open, 160°)
B
3 Open the window until it stops against the stop on the side of
L64453A
the cab.
3 The window is provided with a gas-spring function and closes
automatically the last bit. Mind your fingers when closing the
window.
 Other controls
Operator comfort 63

Rear vision system (optional equipment)

The camera, together with the visual display unit in the cab provide
the operator with a better view rearwards.
The lens on the rear vision camera should be cleaned with a damp
rag when required.

6
5 4
32 L69024A
1
1 On and Off button. When the button is pressed in, a
rearward view is shown on the display unit provided that
the ignition key is in position 1 (running position).
2 Contrast. Adjustment for weaker or stronger image.
3 Light control. Adjustment for brighter or darker image.
4 Light sensor
5 Exposure button. Improves the image in strong sun light
or when it is dark. The button must be kept pressed in.
Therefore, do not make any adjustments while operating.
6 Automatic light control takes place if the button is not
pressed in. If the button is pressed in, the light control has
a fixed setting.
 Other controls
64
 Operating instructions
65

Operating instructions
This chapter contains rules which must be followed to make work-
ing with the machine safe. However, these rules do not relieve the
operator from following laws or other national regulations for traffic
safety, industrial safety and labour welfare.
To avoid the risk of accidents, alertness, judgement and respect for
applicable safety regulations is a condition.

Running-in instructions
During the first 100 hours, the machine should be operated with a
certain amount of care. During the running-in period it is important
to check oil and fluid levels often.
The wheel bolts should be check-tightened after eight hours oper-
ation, see page 174 and 189.
 Operating instructions
66 Safety rules when operating

Safety rules when operating

Operator duties
WARNING! 3 The machine operator must operate the machine in such a way
that the risk of accidents is minimised both for the operator, oth-
An operator of and the management er road users and persons present at the work site.
for a construction machine are
responsible for the working area of 3 The machine operator must be thoroughly familiar with how to
the machine and must turn away any operate and maintain the machine and should preferably un-
person who is not authorised to be dergo required training on the machine.
there when the machine is operating. 3 The machine operator must follow the rules and recommenda-
The operator must keep a good look- tions given in the Operator's Manual, but also pay attention to
out forward, rearward and to both any statutory and national regulations or specific requirements
sides to avoid the risk of running into or risks that apply at the work site.
persons or objects. 3 The machine operator must be thoroughly rested and must
never operate the machine under the influence of alcohol, med-
icine or other drugs.
3 The machine operator is responsible for the load of the ma-
chine both when travelling on public roads as well as when
working on site.
– There must be no risk of the load falling off while operating.
– Refuse to take a load which is an obvious safety risk.
– Respect the stated load for the machine. Pay attention to the
effect of different distances to the centre of gravity and the in-
fluence of different attachments.
3 The machine operator must be in charge of the working area of
the machine.
– Prevent persons from walking or standing under raised lifting
arms, unless they have been made safe or supported.
– Prevent persons from entering or remaining in the danger area,
i.e. a distance of at least 7 m (23 ft) in all directions from oper-
ating machines. The operator may allow a person to remain in
the danger area, but should then observe caution and operate
the machine only when the person is visible or has given clear
indications of where he or she is.
– Prevent persons from being in the cab of a vehicle which is
placed so that there is a risk that the cab may be hit by other
L67245A machines or falling objects, e.g. stones or logs. This does not
The danger area around an operating machine apply if the cab is sufficiently strong or protected to withstand
forms a circle with a radius of least 7 m (23 ft). the impact of such external forces.
3 The machine operator may only allow an instructor on board, if
there is an approved passenger seat.
 Operating instructions
Safety rules when operating 67

Machine operator safety

3 The machine must be operational, i.e. faults which can cause
accidents must be rectified.
3 Suitable clothing for safe handling and a hard hat should be
worn.
3 A loose mobile telephone must not be used, as it may interfere
with important electronics. The mobile telephone must be con-
nected to the electrical system of the machine and have a fixed
external aerial fitted according to the instructions of the manu-
facturer.
3 Always sit in the operator seat when starting the engine/ma-
chine.
3 Keep your hands away from areas where there is a risk of
crushing, e.g. covers, door and window.
3 Always use the lap type seat belt or the three-point belt, if the
machine is equipped with such a belt.
3 Use steps and handholds when entering or leaving the ma-
L66347A chine. Use the three-point grip, i.e. two hands and one foot or
two feet and one hand. Always face the machine – do not jump!
3 The door should be closed:
3 Check that the attachment is properly attached and locked.
3 The vibration (shaking) which arises when operating may be
harmful to the operator. Reduce this by:
– adjusting the seat and tightening the seal belt.
– picking the smoothest operating surface for the machine
(levelling the surface when necessary).
– adapting your speed.
3 The cab is for the protection of the machine operator and it
meets the requirements for Roll Over Protective Structures ac-
cording to the testing standard "ROPS". Therefore, hold firmly
onto the steering wheel if the machine should roll over – Do not
jump!
3 The cab is also designed to meet the requirements for falling
WARNING!
objects, the weight of which agrees with testing methods ac-
It is forbidden to sit or stand in an cording to "FOPS".
unsuitable place on the machine, i.e.
3 The cab has two emergency exits, the door and the right side
on the attachment (bucket, fork, plat-
window.
form etc.) or any other mounted
equipment, so that the operator can- 3 Only step or stand on surfaces which are provided with anti-slip
not handle the machine in a safe way. protection, see page 108.
 Operating instructions
68 Safety rules when operating

Working within dangerous areas

Working within areas where there are pipes, power
lines or cables
3 It is the duty of the employer to know and mark the position of
pipes for gas, water, sewage or power lines or cables on the
work site and to inform the operator about these. Failure to do
so may have legal consequences. When required, local author-
ities and/or communication and power companies should be
contacted regarding maps, drawings and advice.
3 Cables and power lines must be protected against damage in
a suitable way. Electric cables should, if possible, have the
power turned off.
3 Information about where the gas and water can be turned off
should be made available, so that they can be quickly turned
off, if they are ruptured.
NOTE: If digging has to be carried out very close to cables,
pipes or overhead wires, it may be necessary to dig by hand.

High voltage overhead power line

Observe great care when working in the proximity of high voltage
overhead power lines, as electrical flash-over may damage the
machine and injure the operator at fairly great distances from the
power line. Note the following:
The distance sideways between machine and power line must
be:
– at least 2 m (6.5 ft) in case of low voltage.
– 4 m (13 ft) in case of high voltage of at the most 40 kV (line
L68268A normally supported on fixed insulators).
– 6 m (20 ft) in case of high voltage above 40 kV (line nor-
mally carried on suspended insulators).
The distance vertically between machine and overhead power
line must be:
– at least 2 m (6.5 ft) in case of low voltage.
– 4 m (13 ft) in case of high voltage.

The safety distances also apply to any load. The boom kick-out
(lifting height) may have to be adjusted.

Operating under ground

3 Special equipment, e.g. certified engine is required within EU
and EEA countries.Talk to your dealer.

Working in confined areas

3 Check that there is sufficient room for machine and load.
3 Move slowly.
3 Drive in the middle of a doorway which is too narrow to allow
two machines to meet.

Working near danger areas

3 Observe great care near marked danger areas.
3 Do not operate too close to the edge of a quay, ramp etc.

L68291A
 Operating instructions
Safety rules when operating 69

Travelling and operating (working) on a

public road
As a machine operator you are considered to be a road user and
therefore required to know and follow local regulations and nation-
al traffic regulations.
It is important to bear in mind that the machine, in comparison with
the rest of the traffic, is a slow moving and wide vehicle, which may
cause obstruction. Bear this in mind and pay attention to the traffic
behind you. Facilitate overtaking.
L64228A

The use of a SMV-plate (Slow Moving Vehicle plate) is recom-

mended. It should be positioned on the machine where it is easily
visible, not inside the rear window or any other window. It should
be positioned at a height of 0.6–1.8 m (2–6 ft) above the ground,
measured from the lower edge of the plate.
WARNING!
When travelling on a public road,
the lever steering (CDC) must not Travelling on public road
be activated – use the steering 3 The attachment should be empty, lowered to the carry position
wheel. (30–40 cm = 12–16 inches above the ground) and tilted fully
backward. The front end of the material handling arm must be
marked with a red flag.
3 Lock the control levers with the control lever lockout.
3 All working lamps and any rotating warning beacon should be
switched off.
3 Hazard flashers must not be used.
3 Attachments and buckets which obscure the vision must not be
L66358A used.
SMV plate 3 Make sure that large attachments/buckets do not obscure the
travelling lights. According to traffic regulations the area in front
of the machine must be sufficiently illuminated.
3 Additional attachments such as buckets, spades and iron bars
must be thoroughly secured with tensioning straps or chains.
3 A trailer or similar may normally only be used temporarily on a
public road and then only for transporting supplies for the ma-
chine when on site (attachments, tools, fuel, oils etc.).

Operating (working) on a public road

3 Road signs, traffic restricting arrangements and other safety
devices, which may be required when considering traffic speed
L64229A
and intensity or other local conditions, must be used.
3 When moving a machine with a suspended load, special atten-
tion must be observed. When required, request the assistance
of a signal man.
3 Rotating warning beacon may be used:
– on vehicle during road maintenance work, e.g. snow
clearing.
– on attached or connected implement, which is wider than
the vehicle itself.
– when the vehicle constitutes a hindrance or danger to oth-
er traffic
– when operating (working) on or by the side of the road-
way.

L64230A
 Operating instructions
70 Measures before operating

Measures before operating

1 Carry out daily service, see page 153. (Make sure that the
freezing point of the coolant is sufficiently low in cold weather
and that the lubricating oil is intended for winter use.)
2 Clean/scrape the windows.
3 Check that there are no faulty/loose parts or leaks which can
cause damage.
4 Check that the battery disconnect switch is switched on.
5 Check that the frame joint lock has been disconnected.
6 Check that the wheels are not blocked.
7 Check that engine and access covers are closed and that the
radiator casing is closed and secured.
8 Check that there are no persons in the vicinity of the machine,
see page 66.
9 Adjust the operator seat (see page 57) and the steering wheel,
if the machine is equipped with this function, see page 51.
10 Fasten the lap type seat belt or the three-point belt, if the ma-
chine is equipped with such a belt.
11 Check that there is sufficient fuel in the tank.

After operating
3 Fill the fuel tank, as this will counteract the formation of conden-
sation water.
 Operating instructions
Starting engine 71

1 2
Starting engine
R
3
WARNING!
0 The engine must only be stared with the ignition switch in
the cab.

L66305B 1 Place the gear selector to neutral.

2 Turn the key in the ignition switch to running position (1) so that
a system test can take place, the duration of which is 4–5 sec-
onds.
3 At the same time check that all lamps light up and that the
gauges indicate.
4 Turn the ignition key to starting position (3). If the engine does
not start, turn the key back to the "0" position, before making a
new starting attempt. Leave the engine running at low idling for
approx. 30 seconds to ensure satisfactory lubrication of for ex-
ample the turbocharger.
5 Check that all control and warning lamps are extinguished.
6 Check that the attachment is securely fastened to the machine
by pressing it against the ground.
7 Sound the horn.
8 Release the parking brake.
9 Select gear position and increase the engine speed.

Starting engine in cold weather

The preheating function should be used when the coolant temper-
ature is below ±0 °C (+32 °F).
1 Turn the ignition key to running position (1).
2 Press the switch for the preheating. The system can only be
L67275A
activated when the coolant temperature is below +20 °C (+68
°F) and at the most twice during the same starting occasion.
3 The preheating is now engaged and the control lamp is alight.
(The length of time during which the element remains connect-
ed is determined by the coolant temperature).
4 When the control lamp is extinguished, the engine is started by
turning the ignition key to starting position (3).
5 The preheating is automatically reconnected at a coolant tem-
WARNING! perature below +20 °C (+68 °F) whereby the control lamp
Starting gas (ether etc.) must not be lights up.
used at the same time as the preheat-
ing element. NOTE: If the control lamp continues to light after a period of
50 seconds, the preheating is still connected. Should this be
the case, check the function of the element as there is a risk
of overheating.

3 Leave the engine running at low idling for 30 seconds so that

the oil in the engine, transmission, hydraulic system and axles
has warmed up and become sufficiently fluid to provide proper
lubrication.
3 To race the engine immediately after it has been started may
also endanger the lubrication and cooling of the turbocharger
with great risk of bearing seizure as a consequence.
 Operating instructions
72 Starting engine

Gear shifting
Automatic Power Shift (APS II)
(Gear selector in speed gear position 3 or 4)
The shift modulation allows the machine operator to select differ-
ent automatic shifting programmes (modes) depending on the op-
erating conditions.

Operating in the APS position

3 Turn the gear selector control to gear position 3 or 4.
3 Set the shift mode selector within the automatic range (not the
manual).
Mode selector 3 Select directional gear.
3 Accelerate and the machine will start in 2nd gear (basic gear).
If the machine is already moving, it will engage 3rd gear auto-
matically.
3 Up- and downshifts are made between 2nd – 3rd – 4th gears
forward and between 2nd – 3rd in reverse.
3 When the direction of travel has been changed the machine will
start off in 2nd gear.
3 For shifting down to 1st gear, see "Kick-down function" on the
next page.

Position LIGHT
3 The first position means that the gear shifting will take place at
low engine speeds and is preferably used for transport opera-
tions without load.
3 The second position means that the gear shifting will take place
at a slightly higher engine speed than in the first position and is
used for lighter loading-carrying operations.
3 With the accelerator fully depressed, upshifting takes place ac-
cording to the HEAVY position.
3 The best utilisation is obtained if the accelerator is not de-
pressed fully, as the difference in engine speed at which up-
shifting takes place between the LIGHT and HEAVY positions
will be more noticeable.
3 Results in lower fuel consumption and lower noise level.

Position HEAVY
3 The machine does not shift until higher engine and travelling
speeds have been reached.
3 Preferably used in cases where the machine changes gear
when operating uphill or when the rolling resistance is great.

Position MAN (manual)

3 After starting gear shifting is done manually, see page 72.
 Operating instructions
Starting engine 73

Manual gear shifting

3 Should be used if special operating conditions so require.
3 Select position MAN of the gear shifting mode selector, see the
next page.
3 Select a suitable gear by turning the gear selector control to the
required gear position and then select travelling direction for-
ward or rearward.

Directional gear
Selector in position N = Neutral
Selector in position F = Operating forward
Selector in position R = Operating rearward

L66350A

WARNING!
The selector control must, for reasons of traffic safety,
under no circumstances be moved to neutral when operat-
ing downhill – no engine retarding effect.
Never leave the machine with the selector in forward or
reverse while the engine is running – there is a risk that the
machine may begin to move.

When changing from forward to reverse or vice versa, the speed

of the machine and of the engine should be reduced as much as
possible, particularly if the machine is working on firm ground.
Do not shift between Forward and Reverse at higher speeds than
2nd gear.
 Operating instructions
74 Starting engine

Kick-down function
Kick-down is obtained, if the mode selector is within the automatic
range, the gear selector control is in either of positions 2, 3, or 4
and either of the kick-down buttons is actuated.
L66351A

3 When the kick-down button is pressed, 1st gear will be en-

gaged if the travelling speed already is below 10 km/h
Kick-down button, gear selector control (6.2 mph) or if the speed drops below 10 km/h (6.2 mph) within
8 seconds after the button was depressed.
3 When 1st gear has been engaged the buzzer will give off one
short pip.
3 1st gear will remain engaged unless the kick-down function
switch is actuated a second time or if the engine speed be-
comes extremely high (when the switch is actuated a second
time, 2nd gear will be engaged).
3 If the direction of travel is changed, the machine will start off in
2nd gear, provided automatic shifting is selected.

NOTE: If the machine, as optional extra, is equipped with lever

steering (CDC) the kick-down function is also available on the
arm rest.

Kick-down button, control lever carrier

Engine retarding / downshifting
With the aid of the button for engine retarding / downshifting it is
possible to achieve an immediate downshift in one or two stages
or prevent unwanted upshifting. In this way warming up of the axle
oil is reduced.
3 One press of the button at higher speeds, will result in a down-
3 2 1 shifting from 4th to 3rd gear.
3 One further press of the button at a lower speed, will result in a
downshifting to 2nd gear.
3 If the switch is kept in the pressed-in position, upshifting to the
next higher gear is prevented, which can be used when operat-
ing downhill or when approaching a vehicle which is to be load-
ed.
L66355B
NOTE: If certain critical rotational speeds and travelling
speeds are exceeded, upshifting takes place.
Engine retarding
3 If the engine or transmission speed become too high, the red
central warning lamp flashes, the buzzer sounds and the alarm
text "Overspeeding On Selected Gear" is shown.
3 Under these circumstances, lower the travelling speed, or se-
lect a higher gear to reduce the engine speed.
 Operating instructions
Steering 75

Steering
The machine has articulated frame steering controlled by a load-
sensing, hydrostatic steering system.

57179 Lever steering, CDC (optional equipment)

The system consists of a folding arm rest where three functions
are collected: steering, forward/reverse and kick-down. The sys-
tem is activated with the button on the arm rest (see the next
page). The arm rest must be lowered in order to be able to activate
the functions.
Small physical effort is required to operate the lever steering. The
distance the lever is moved is proportional to the speed at which
the steering system reacts. This means that it is possible to make
very slight movements when one wishes to do so.
The steering wheel always remains functional.
The control lamp on the front left instrument panel remains on
while the CDC functions are activated.
By alternating between using lever steering and steering wheel
steering the operator will have a more varied pattern of movement.

WARNING!
When operating on a public road, it is prohibited to have
WARNING the lever steering activated – use the steering wheel.
Also when operating at high speeds (above 20 km/h =
12.4 mph) on a work site, always use the steering wheel in
order to avoid accidents.

CDC

The CDC functions will be automatically deactivated, if the

gear selector control by the steering wheel is moved from
neutral.

Small physical effort is required to operate the lever steering. The

L66357A distance the lever is moved is proportional to the speed at which
the steering system reacts. This means that it is possible to make
very slight movements when one wishes to do so.
The steering wheel always remains functional.
 Operating instructions
76 Steering

1 Activating (CDC)
In order to be able to use the steering, forward/reverse and kick-
down functions from the arm rest, the arm rest must be lowered
and the system activated with button 1.
To make it possible to activate the system, the following steps must
first be carried out:
– The arm rest must be lowered.
– The directional gear selector on the arm rest and ordinary gear
selector control must both be in neutral.
– The engine must be running, but the machine must be station-
ary.

2 Steering lever
Small physical effort is required to operate the lever steering. The
distance the lever is moved is proportional to the speed at which
the steering system reacts. This means that it is possible to make
very slight movements when one wishes to do so.
1 Activating CDC The steering wheel always remains functional.
2 Steering lever
3 Kick-down button
4 Directional gear selector F-N-R 3 Kick-down button
With the kick-down button pressed in = The machine shifts down
to 1st gear if the automatic shifting range has been selected with
the mode selector and the gear selector control is in either of po-
sitions 2, 3 or 4.
For further instructions, see page 74.

4 Gear-shifting function (Forward/Reverse)

With the front end of the switch pressed down = Forward drive.
With the rear end of the switch depressed = Reverse drive.
There is a neutral position between the forward and reverse posi-
tions.
NOTE: The ordinary gear selector control always has priority,
i.e. if the ordinary gear selector control is actuated, the selec-
tion made from the armrest is cancelled.
 Operating instructions
Braking 77

Braking
Brake smoothly. This is particularly important when operating with
a load and on slippery ground. If required during certain opera-
tions, the power transmission can be made to automatically disen-
gage when the brakes are applied, see page 24.
Engine retarding with the aid of the downshift button may be ad-
L57142
vantageous, particularly when operating downhill. In this way it is
Switch, transmission disengage- possible to reduce the warming up of the axle oil, see page 74.
ment

WARNING!
The transmission disengagement function must not be
used during transport operation.

Brake test
(Checking service brakes)
The brake test is carried out with the aid of computer software,
which measures the average retardation of the machine. The test
can be carried out by the machine operator from the display unit.

WARNING!
Brake test and checking the parking brake must only be
done within an area where it cannot cause accidents.

Conditions
1 Brake test must only be done within an area where it cannot
cause accidents (risk of being run into from behind etc.).
2 The ground must be level and the surface have good friction.
3 The machine must not be loaded.
4 The travelling speed of the machine must exceed 20 km/h
(12.4 mph) when the service brakes are applied.

Acceptable values can only be obtained if the test is car-

ried out on dry asphalt, dry concrete or other similar sur-
faces.
 Operating instructions
78 Braking

Measuring procedure
Make sure that the prerequisites according to the previous page
are met.
1 Select AXLES/BRAKES from the keyboard.
2 Select the sub menu BRAKE TEST with the arrow key.
3 Move off (gear selector position A).
When the speed exceeds 20 km/h (12.4 mph) there will be a
short pip signal and the display unit will show "0.0 m/s 2 0.00 g",
which means that the speed required for the test has been
reached.
4 If the display unit instead shows "X.X m/s2 X.XX g", the speed
is too low (below 20 km/h = 12.4 mph).
To obtain credible and useful test values, the brake applica-
tion must be carried out:
3 Without wheels locking or skidding.
3 With the brakes applied as hard as possible and without letting
up the brake pedal during the test.

Result and evaluation

The test result will be shown on the display unit when the machine
has stopped, i.e. the speed is 0 km/h, and remains on the display
until the speed again exceeds 10 km/h (6.2 mph).
In order to eliminate tests during which the wheels have locked,
brake applications where the retardation exceeds 8 m/s2 (0.82 g)
are not registered.
In this case “X.X m/s2 X.XX g” will be shown on the display unit.

Minimum value for brake test: 4.75 m/s2 (0.48 g)

3 If the measured retardation is less than 4.75 m/s 2 (0.48 g), a
new test has to be carried out.

If this test too shows a value below 4.75 m/s2 (0.48 g), the brake
system must be checked at an authorised workshop.
 Operating instructions
Stopping machine 79

Stopping machine
1 Lower the engine speed.
2 Apply the brakes and when the machine is stationary, move
the gear selector control to neutral.
3 Lower the attachment to the ground.
4 Apply the parking brake after the machine has come to a com-
plete standstill.
5 Run the engine at low idling a couple of minutes before stop-
ping it in order to safeguard the lubrication and cooling of the
turbocharger.
6 Turn the ignition switch key counter-clockwise so that the con-
trol lamps go out and the engine stops.

WARNING!
When you are entering or leaving the machine, always face
the machine and use the steps or hand holds to avoid slip-
ping. Always use the "three-point" grip, i.e. both hands and
one foot or both feet and one hand, when entering or leav-
ing – Do not jump!

If the operator has to leave the cab while the engine is running,
care must be taken, so as not to turn the steering wheel uninten-
tionally. This applies particularly if the steering wheel is provided
with a steering knob.

L64417A
 Operating instructions
80 Parking

Parking
1 If possible, place the machine on level ground. If this is not
possible, block the wheels so that the machine cannot start
rolling. Lower the attachment against the ground.
2 Check that all switches and controls are in the "off" position or
in neutral.
3 Apply the parking brake after the machine has come to a com-
L68292A
plete standstill.
4 Remove the keys.
5 Turn off the current supply with the battery disconnect switch,
if the machine is to be left unattended for some time.
6 Lock all covers, windows and the door.

Long-term parking
1 Carry out the measures as described above.
2 Wash the machine and touch up the paint finish to avoid rust-
ing.
3 Treat exposed parts with anti-rust agent, lubricate the machine
thoroughly and apply grease to unpainted surfaces like lifting
and tilting cylinders etc.
4 Check the tyre pressure and protect the tyres against strong
sunlight.
5 Fill the fuel tank and the hydraulic oil tank to the max. marks.
6 Cover the exhaust pipe (parking out-of-doors).
7 Make sure that the freezing point of the coolant is sufficiently
low (in cold weather).

Check after long-term parking

WARNING! 3 All oil and fluid levels.
3 Tension of all belts.
If the engine cannot be started: As
the braking and steering functions 3 Air pressure
will be limited in this situation, tow- 3 Air cleaner
ing must only be done as an emer-
gency, and over the shortest
possible distance by trained per-
sonnel. If possible, transport the
machine on a trailer.
 Operating instructions
Recovering/towing 81

Recovering/towing

WARNING!
Before taking any steps in preparation for recovering or
towing, the parking brake must be applied and the wheels
blocked to prevent the machine from rolling. The greatest
care must be taken in connection with towing to avoid seri-
ous injury which at worst could be fatal.

Measures
3 If possible, the engine should be running to make the brakes
and steering operational.
3 If it is not possible to start the engine or for any other reason it
is not possible to build up pressure needed to release the park-
ing brake, it is possible to release it mechanically, see page 83.

Recovering
3 Use a bar which should be connected to the towing device at
the rear on the machine to be towed and tow it to a suitable
place or a trafficable road. To avoid oblique loading, pull the
machine straight rearward.
NOTE: The attaching eyes on the rear frame on the inside of
L67322A
the rear wheels must not be used for recovering (only for lift-
ing and lashing the machine).

Towing
3 Use a towbar connected to the towing device at the rear of the
machine as described above, or a wire rope secured through
the eyes on the front axle attachment. (If the brakes on the ma-
chine do not work, a towbar must be used.)
3 The towing vehicle or machine must be at least as heavy as the
machine to be towed and must have sufficient engine power
and braking capacity to pull and brake both machines in any up
or down hills.
3 Do not tow further than absolutely necessary as otherwise the
transmission may be damaged.
3 When towing further than 10 km (6 miles) or when towing at a
speed exceeding 10 km/h (6 mph), both the front and the rear
propeller shafts must be removed, or, as an alternative, the ma-
chine must be transported on a trailer.

Removing propeller shafts

1 Place the machine in service position, see page 107.
2 Release all brakes.
3 Remove the propeller shaft bolts and detach the propeller
shafts from the drive axles.
NOTE: The parking brake action is lost after removing the pro-
peller shafts.
L67324A
NOTE: It is not possible to start the engine by towing.

Follow national regulations where required.

 Operating instructions
82 Recovering/towing

After recovering / towing

Before the towbar or wire rope is removed, the following safety
measures should be taken:
1 If possible place the machine on level ground.
2 Block the wheels to prevent the machine from rolling.
3 Restore the parking brake, if it has been mechanically re-
leased.

NOTE: If the machine is left without having restored the park-

ing brake, this must be indicated by a label on the steering
wheel with the information that the parking brake has been
disabled.
 Operating instructions
Recovering/towing 83

Parking brake, mechanical release

If it is not possible to start the engine or for any other reason it is
not possible to build up pressure needed to release the parking
brake, it is possible to release it mechanically.
NOTE: However, this is only allowed in order to enable tow-
ing. Immediately after the towing has been completed, the
parking brake must be restored.

WARNING!
Always block the wheels before releasing the parking brake
to prevent the machine from rolling.

Releasing
L68185A
– Remove the three plugs according to figure. Oil will leak out.
– Temporarily replace these with three bolts (M10 x 90 mm) and
Releasing parking brake washers (the bolts are included in the tool bag for the machine).
– Tighten the bolts alternately until they bottom.

Restoring
– Unscrew the bolts, one at a time. Some oil will leak out.
– Re-install the plugs.
– Put the bolts back in the tool bag for the machine.
NOTE: If the machine is left without having restored the park-
ing brake, this must be indicated by a label on the steering
wheel with the information that the parking brake has been
disabled.

WARNING!
Hot oil can cause burns.
 Operating instructions
84 Transporting machine

Transporting machine
C
11 026 730

WARNING!
If the machine is driven across from a loading dock onto
the platform of a truck or trailer, make sure that this vehicle
L64511C is securely braked, i.e. the wheels blocked and that there is
no risk that the vehicle will tip or tilt in a dangerous way as
A B A B A the machine is driven across.
Transport the machine with the bucket in the
direction of travel of the transporting vehicle. NOTE: To avoid air being forced down the exhaust pipe when
transporting, it should be covered with suitable protection (C)
(not plastic). Otherwise the turbocharger may be damaged.

On another vehicle
3 If the machine is lifted up onto another vehicle, the frame joint
must be locked.
– Use attaching points intended for lifting and lock the frame
joint.
3 If the machine is driven up onto another vehicle, the frame joint
must not be locked.
3 Tie down (lash) the machine.

Lashing
3 Block the wheels (B).
3 Tie (lash) the machine down using attaching points (A) intend-
2m ed for this purpose, so that it cannot tip or begin to roll.
495
4898

Lifting
A
L67514

5m 6,5 m 3 Lift the machine by the therefore intended lifting eyes (see fig-
ure) and lock the frame joint.

Across ramp
3 First check that the ramp is amply wide enough and has the re-
L64512B quired strength and that it will not be displaced.

In elevator or other narrow space

1 Reverse the machine in.
2 Apply the parking brake and stop the engine before starting the
elevator.

Also follow national or state regulations.

 Operating techniques
85

Operating techniques
The following pages contain advice and instructions on how to op-
erate the machine and examples of how the most common attach-
ments are used. It is important that the correct technique is used
to obtain safe and efficient use of the machine.
The machine is equipped with load-sensing hydraulics, which
means that a low engine speed is sufficient for all handling, as full
oil flow is always available. The system therefore uses less fuel
and provides a higher operator comfort.

L64231A

Accidents
3 Accidents and also incidents should be reported to the site
management immediately.
3 If possible leave the machine in position.
3 Only take necessary action so as to reduce the effect of dam-
age, especially personal injuries. Avoid action which may make
an investigation more difficult.
3 Wait for further instructions from the site management.
 Operating techniques
86 Attachments

Attachments
Using the correct attachment for a particular job is a deciding factor
1 when it comes to the capacity of the machine.
The machines have either direct-mounted attachments or attach-
ments mounted in a bracket which allows rapid changes of attach-
ments.
When choosing attachments, follow the recommendations in the
Attachment catalogue or documents issued by Volvo CE. Because
of great variations in for example usage, material and working en-
2 vironment, one may deviate from these recommendations. In such
cases, the Volvo CE dealer should first be contacted for further in-
formation and approval. You are yourself responsible for the safety
regarding the combination of machine – attachment and also that
the national safety requirements are met.

– According to the EU Machine Directive the CE marking must be

3 shown on the machine product plate. This marking therefore
also covers the attachments which are designed by Volvo CE,
as they are an integrated part of the machine and adapted to
the machine. Volvo CE is not responsible for attachments man-
ufactured by other companies. Such attachments must be CE
marked and accompanied by a Declaration of Conformity and
user instructions.
4

L64525B

The five most common types of buckets:

1 Straight bucket without teeth

(Loose material, sand, earth, fertilizer).
2 Straight bucket with teeth
(Hard material, gravel, clay, surface stripping)
3 Spade-nose bucket without teeth.
(Material which requires good penetration
force, gravel, finely blasted rock and ore).
4 Spade-nose bucket with teeth.
(Hard and rocky material,
hard gravel and blasted rock).
5 Levelling bucket
(Finer stripping work, moving top soil and lev-
elling filling material).
 Operating techniques
Attaching and disconnecting attachments 87

Attaching and disconnecting

attachments

WARNING!
Never use an attachment until you have checked that it is
securely fastened and that the attachment including
hydraulic hoses, connections and similar are undamaged –
your safety is involved.

3 Make sure that the hydraulic oil in the attachment, which is to

be connected, is not contaminated (foreign particles, water
etc.) and that it is of the same quality as that of the machine it-
self.

WARNING!
Check that the attachment is properly locked by pressing
the front edge of the attachment against the ground, so that
the front end of the machine begins to rise slightly, see the
figure below.

If you are uncertain as to whether the attachment is securely

locked, you must visually check that the locking pins of the
attachment bracket are in the locked position.

L61721A
 Operating techniques
88 Attaching and disconnecting attachments

Separate attachment locking

Connecting
1 Release the locking pins by pressing switch 2.
2 If necessary, raise the pressure by pressing switch 1.
3 Tilt the attachment bracket forward approx. 15° and align the
upper attaching points of the bracket with the upper attaching
points on the attachment.
L57149
L57138

4 Raise the lifting arms until the attachment rests in the bracket
1 Raised pressure 2 Attachment lock and tilt the bracket rearward until the attachment is level.
5 Lock the attachment with switch 2, (if necessary raise the pres-
sure with switch 1).
Check that the attachment is properly locked by pressing the front
edge against the ground. If it is locked, the front wheels will begin
to rise.

WARNING!
When connecting attachments, the operator should make
sure that the expected effect is obtained when moving the
control levers. An unexpected movement may possibly
result in an accident.
Always check the function before the machine is put to
L67276B work and that hydraulic hoses etc. for the attachment can
Attachment bracket lock- move freely and are sufficiently long throughout the whole
ing pins in unlocked position working range of the lifting arms and the tilting function.
Extension hoses are available – contact an authorised
dealer workshop.

Disconnecting
1 The attachment should be in a level position on the ground.
2 Release the locking pins by pressing switch 2.
3 If necessary, raise the pressure by pressing switch 1.
4 Lower the lifting arms so that they disengage from the attach-
ment.
5 Reverse away from the attachment.
L67276C
Tilt forward approx. 15° and hook the
bracket into the upper attaching points on
the attachment

WARNING!
Switch (2) for attachment locking must only be actuated in
connection with the changing of attachments. Otherwise
the pressure may be lost and as a consequence the attach-
ment may work loose and cause injuries.

WARNING

L67276D
L67523A

11 111 506
Lift, tilt rearward until level and lock with
the locking pins of the attachment
bracket
 Operating techniques
Attaching and disconnecting attachments 89

Pressure release
Residual pressure in the hoses makes it very difficult to part or join
up the quick-action coupling halves.
This is facilitated, by releasing the pressure in the hydraulic sys-
tem, when, for example, you want to disconnect a hydraulic hose:
1 Stop the engine.
2 Ignition switch in position 1.
3 The control levers for the function in question are moved for-
ward and rearward several times. Leave the control levers in
their respective end position for approx. five seconds.

The pressure in hoses from timber grapples can be released in the

following way:
1 Close the clamping arm fully.
2 Make a quick movement with the lever in the opposite direc-
tion.
The hoses become "slack" when the pressure is released.

The attachment should always rest on the ground when re-

leasing the pressure.

Excess pressure in a hydraulic attachment can be released by

slackening the lock nut between the hose and the hydraulic pipe
and then tightening it again. Meanwhile watch the attachment.

Collect the surplus oil.

 Operating techniques
90 Accumulators, releasing pressure

Accumulators, releasing pressure

The pressure in the accumulators for brake system, Boom Sus-
pension System and servo system is released as shown below:

WARNING!
L66320A
Even if the engine has been stopped, there is still an accu-
mulated pressure in the system. If the system is opened,
without having first released the pressure, oil under high
pressure will jet out and this could cause injuries.
Even retightening of leaking couplings and unions should
not be done until the pressure in the system has been fully
released.

Brake system
1 Stop the engine.
2 Depress the brake pedal several times (30–40 times).

Boom Suspension System (BSS)

1 Move the gear selector to neutral.
2 Start the engine and run it at low idling.
3 Tilt inward and lower the lifting arms to the ground.
4 Engage floating position with the switch.
Floating position 5 Move the lifting/lowering control lever to the lowering position
(floating position).
6 Set the switch in the position for gear-dependent Boom Sus-
pension System (the centre position) and wait for approx. 30
seconds.
7 Stop the engine.

Servo system
1 Stop the engine.
L67478A
2 Ignition switch in position 1.
Boom Suspension
System – BSS 3 Move the control levers forward and backward several times.

WARNING!
Discarded accumulators must not be thrown away unless
they first have been taken care of by a workshop and care-
fully "punctured".
If a pressurised accumulator is heated, there is a risk that it
may explode.
 Operating techniques
Buckets 91

Buckets
When the machine is used with a bucket, a working load of 50% of
the tipping load for a fully steered machine is permissible.
Depending on application and/or machine size the manufacturer
often recommends a utilisation lower than 50%.
For information regarding weight, capacity, load, edge savers,
etc., see the Attachment Catalogue.

WARNING!
The bucket must not be used for transporting or lifting peo-
ple – as this might lead to accidents.

Choosing bucket
3 The choice of bucket is dependent on the condition of the ma-
terial (hard/loose), its density (heavy/light) and on the tipping
load of the machine.
3 A too large bucket relative to the density of the material and the
tipping load of the machine will give the impression that the ma-
chine is weak and unstable and will not increase the productiv-
ity.
For guidance on the choice of bucket, see the Attachment Cata-
logue.

IMPORTANT! Check-tighten the bolted joints at the edge sav-

ers and segments to prescribed torque after approx. four
hours of operation. Thereafter check the torque now and
then.

Tightening torque for edge savers and segments with

bolted joints (bolt grade 10.9)
Size Tightening torque
M16 275 ±45 N m (203 ±33 lbf ft)
M20 540 ±90 N m (398 ±66 lbf ft)
M24 900 ±140 N m (664 ±103 lbf
ft)
1 1/4” 2160 ±345 N m (1593 ±254 lbf
ft)

Bucket operation
To obtain efficient and safe operation it is important to bear the fol-
lowing points in mind:
3 Select the correct bucket.
3 Level the ground at the work site as far as possible and make
sure the ground is firm.
3 Avoid wheel spin by adapting the engine speed and by trans-
ferring as much weight onto the front wheels as possible. This
is achieved by slightly raising the bucket after it has begun to
enter the material.
3 Work with a straight machine against the material to obtain the
greatest penetrating ability. This also contributes to a reduced
tyre wear.
 Operating techniques
92 Buckets

Gravel and heap loading

1 Adjust the bucket so that it is level and lower it to the ground
just in front of the gravel heap.
2 Enter the material in 2nd gear + kick-down. When the machine
has nearly come to a standstill because the maximum tractive
effort of the machine has been reached, begin to raise the
bucket while at the same time tilt backward with short control
L64238A
lever movements.
If possible avoid tilting the bucket forward when filling it. Ex-
aggerated lever movements causes wheel spin. Never move
into the material at a high speed.

Suitable bucket: Straight bucket with or with-

out teeth.
Suitable gear: Gear selector in position 2 or
4
Mode selector: Position LIGHT
Boom Suspension System: Gear-dependent position

WARNING!
Pay attention to the risk of falling material. Falling material
can cause severe accidents if due care is not taken.

Excavating
3 When excavating and surface stripping, start by angling the
bucket 2–3° downward.
3 Operate in 1st gear and at low engine speed. Gradually in-
crease the engine speed at the same time as you raise the
bucket slightly.
3 If the ground conditions are poor and the wheels tend to spin,
use the differential lock.
NOTE: You must never engage the differential lock when one
of the wheels is spinning. Let up the accelerator until the
wheel stops.

Suitable bucket: Straight with or without teeth

(alt. levelling bucket)
2-3 L64242A
Suitable gear: Gear selector in position 1
Mode selector: Position LIGHT
Boom Suspension System: Not activated
 Operating techniques
Buckets 93

Rock loading
3 Correct engine speed is of great importance – too high engine
speed causes wheel spin.
3 Drive into the material head on to avoid oblique stresses which
can harm the lifting arm system.
3 The edge of the bucket must find its way under and between
the stones, which means that you must watch the bucket care-
fully as it enters the material.
3 If a stone has become wedged, try a new angle of approach,
but avoid exerting pressure on the corner of the bucket.
3 Avoid driving up into the material, as there is then a great risk
of damage to the tyres by the sharp blasted pieces of rock. Also
remove stones that have fallen out of the bucket.

L64240A
Suitable bucket: Spade-nose bucket with or
without teeth.
Suitable gear: Gear selector in position 2
Mode selector: Position LIGHT
Boom Suspension System: Gear-dependent position

Transporting load (loading – carrying)

3 The bucket should be fully tilted backward and kept in the car-
rying position 30–40 cm (12–16 in) above the ground.
3 Keep the transporting road even and free from stones and oth-
er objects. There is always spillage from a too full bucket.
3 Even out the road on the way back if necessary.

Suitable maximum speed: Approx. 15 km/h (9.3 mph)

Suitable gear: Gear selector in position A
Mode selector: Position LIGHT
Boom Suspension System: Gear-dependent position

When operating where gear-shift hunting arises, select the

HEAVY mode as the machine then must reach a higher travel-
ling speed before upshifting takes place. Example: When op-
erating up long inclines during loading/carrying work.

NOTE: Remember that the stability of a heavily loaded ma-

chine changes when it is steered.
 Operating techniques
94 Buckets

Dumping load

WARNING!
If visibility is limited by the load or the attachment, great
care must be taken. Walk around the machine before start-
ing and make sure no persons enter the working area of the
L64241A machine. If you are uncertain, raise the load and check the
conditions in the operating area by looking under the load
and operate at low speed. If necessary, arrange for a signal-
ling person to take charge and to help the operator under
"tricky" circumstances. Great care must be taken to pre-
vent injuries and damage to property.

3 If you are working on an incline, try to arrange so that the load

can be dumped uphill. This affects the stability of the machine
in a positive way.
3 Keep the bucket as close to the platform or bin as possible to
achieve a smooth dumping and better control of the positioning
of the load.
3 When loading rock, try to fill the first bucket with as fine material
as possible in order to soften the impact of subsequent larger
pieces.

Positioning of transporting vehicle

3 The positioning of the hauler (transporting vehicle) is of great
importance for making the loading operation efficient.
3 The operator should indicate where the transporting vehicle is
to stand, suitably by "pointing" with the bucket. Having done so
the operator is then responsible for that the place is safe.

Levelling
3 The bucket should lie flat against the ground. To be able to fill
any hollows you should have material in and in front of the
bucket when operating forwards.
3 To finish off the levelling operation, keep the edge of the bucket
slightly downward and reverse while pressing the bucket lightly
against the ground.
3 The final touch can be done by reversing with the bucket flat
against the ground and with the lifting/lowering lever in floating
position. A straight bucket with a long bottom is recommended
to produce a neat job.
3 If a dozer blade, snow plough or sweeper etc. is used, it may
advantageous to have the single-acting lifting function en-
gaged. This allows the attachment to follow any unevenness in
the ground by "floating". This also helps to maintain the steering
ability and the tractive force of the machine. The attachment al-
ways returns to the preset position, see page 18.

Suitable bucket: Straight without teeth (alt.

levelling bucket)
Suitable gear: Gear selector in position 1 or
2
Mode selector: Position LIGHT
Boom Suspension System: Not activated
 Operating techniques
Timber grapples 95

Timber grapples
There are five different timber grapples:
A Unloading grapple has short tines which makes it easier to fill
the grapple when unloading a transporting vehicle.
B Sorting grapple has relatively long fork tines, which can be
placed in parallel with the ground. This facilitates filling the
grapple when taking from a stack and a sorting bin.
C General purpose grapple has longer fork tines than the sort-
ing grapple and can be used for handling whole trunks when
sorting or grabbing single trunks.
L64245A
Tree-length grapple is a wide grapple which also can handle sin-
gle trunks. This grapple too has slightly longer tines than the sort-
ing grapple.
Tropical grapple also is wide and has two separate clamping
arms in order to get a secure grip on large, heavy logs.

A B C
L64526A

The CEN standard EN 474-3 applies within the EU, which means
that nominal operating load is expressed as a percentage of the
tipping load. In accordance with this, Volvo CE have chosen to
adapt its internal standard for stating the capacity of timber grap-
ples.
The recommended maximum loads apply for combinations of tim-
ber grapples and wheel loaders which are equipped with approved
counterweights for timber handling.
Any equipment added to the attachment reduces the rated operat-
ing load.
In countries outside the EU and EEA other safety requirements
may apply, therefore, always observe local regulations.
 Operating techniques
96 Timber grapples

Working with timber grapples

Unloading vehicle
Take great care when filling the grapple so as not to damage the
load stakes on the bunks of the vehicle.
1 Approach the vehicle which is to be unloaded with a raised and
fully open grapple.
2 Tilt the grapple forward and lay it down over the load.
3 Close the clamping arm and begin to tilt slightly upward. Then
L64247A repeat alternate closing and upward tilting of the grapple until
it is full.
NOTE: Take great care when unloading a vehicle, particularly
when there are only a few logs left. If the grapple should grip
round the far edge of the platform this could lead to damage.

Stacking
On machines with Boom Suspension System it is recommended
that speed-dependent position is selected. The precision increas-
es and the risk of "crows nests" is reduced.
NOTE: Do not use floating position when handling timber.
1 Keep the grapple as near the stack as possible to prevent logs
falling down.
2 Tilt the grapple slightly forward.
L64246A
3 Carefully open the clamping arm fully so that the logs can roll
out of the grapple.
4 Reverse carefully and at the same time lower the grapple and
hold it close to the load to prevent logs from falling.

3 When using a grapple with heel/kick-out, there is no need to tilt

the grapple forward. The lifting height of the machine is better
utilised and one can build higher stacks. The heel kick-out can
also be used as a counter hold when handling single logs.
Basic rule: Make sure that the logs leave the grapple without fall-
ing.

Suitable gear: Gear selector in position A

Mode selector: Position LIGHT
 Operating techniques
Timber grapples 97

Picking up from a stack

Low stack:
1 Keep the grapple tines flat against the ground with the grapple
fully open.
2 Enter the grapple into the stack and close the clamping arm as
far as possible.
3 Carefully reverse while closing the grapple further.

High stack:
1 Begin as high as possible and tilt the grapple tines slightly for-
ward with the grapple fully open.
2 When the grapple is well into the stack, close it.
3 Follow through with the grapple so as to avoid logs falling
down under the grapple.
If logs fall between the grapple tines, carefully lower the load
to the ground, reverse and try to pick up the load again. Make
sure not to damage the logs.
A heel/kick-out makes it possible to stack the logs higher and to
keep the ground in front of the wheels of the machine clear of logs.

Operating with whole trunks

3 Pay special attention to that the centre of gravity of the timber
is correctly positioned so as to maintain a satisfactory side-sta-
bility of the machine.
3 Make use of a signal man when operating where the view is re-
stricted, see page 103.

WARNING!
The large clearance radius when handling timber, means
that the operator must take great care not to hit anyone or
anything in the vicinity of the machine.
 Operating techniques
98 Pallet forks

Pallet forks
IMPORTANT! Only pallet forks approved for the machine by
B
Volvo CE may be used.
Fork tine back frame and fork tines must be dimensioned to with-
stand loads which the lifting capacity of the machine permits.
A (90o) ;;;;The fork arms are dimensioned according to ISO 2330 and are
classified together with the machine according to the norms in
C force.
L66614A

Checking fork tines 3 Check the pallet forks regularly as regards wear. It is particular-
A Angle
ly important to check the heel of the fork tine.
B Attaching lugs 3 The fork tine should not be used any more if:
C Thickness – the fork tine has been worn down to 90% of its original
thickness.
– the angle between fork tine and shank has become great-
er than 93°.
– the attaching lugs are worn or cracked.
3 Cracks or wear must not be made good by welding.
L66613A

Fork tine extensions

Fork tine extensions are used when handling light material with low
Marking density and it is marked with maximum load.
1 Max. load per tine (kg) *)
2 Distance to centre of gravity in mm for max-
imum load
3 Thickness of fork tine at delivery

*) Must not be confused with rated operating Operating with pallet forks
load for the respective loader model.
The most important points for work with pallet forks are:
3 The operator should have suitable training.
3 The operator is responsible for that permissible load values are
not exceeded.
3 The fork makes a semi-circular movement when it is raised.
Therefore, start raising the fork a little bit away from the place
where the load is to be placed.
3 The fork must not be raised other than when stacking or depos-
iting pallets.
3 When operating without a load in the fork, the tines should be
L64252A
held low and tilted upward.
3 When stacking material, the fork tines should be kept horizon-
tal.
3 The travelling speed should be adapted to the ground condi-
tions.

NOTE: For heavy work which require great break-out force,

e.g. breaking out tree stumps and carrying marble blocks –
use attachments approved by Volvo CE.

Suitable gear: Gear selector in position 4.

Mode selector: Position LIGHT

L64251A
Boom Suspension System: Gear-dependent position or
not activated
 Operating techniques
Pallet forks 99

Picking up a load
3 Choose fork tines with a correct length so that they do not pro-
trude outside the load. Previously deposited pallet or goods
may be damaged as the penetrating force of the fork tines is
very great.
3 Place the load as close to the vertical shank of the fork as pos-
sible.
L64253A
3 Lift the load with the least possible inclination of the pallet fork.
3 There may be deviations from the complete parallel movement
(see the Specifications) and this may affect the use of the fork.

Operating with a load

3 Keep the load low 30–40 cm (12–16 in) above the ground to
achieve the best possible stability and vision.
3 Tilt the load rearward to hold it more secure.
3 If the load obscures the vision, reverse the machine to the
place where the load is to be deposited.
3 Adapt the speed to the existing conditions.
L64255A

3 When handling high loads, use a special load support.

WARNING! Combi-forks
When detaching pallet forks from The combi-fork is a good alternative for material handling, when
the machine, stabiliser legs should the load to some extent has to be held in position. Here a special
be placed against the ground. combi-fork frame is used for mounting standard fork tines.
Combi-fork back frames are available in two versions:
3 The one-piece clamp is most suitable for handling palletised
goods and for round timber.
3 The twin arm clamp is used in the pulp industry and on building
sites, where both palletised goods and compressed material
(waste paper, packaging material etc.) are handled.

Approval and legal provisions

WARNING The permissible rated operating load capacity according to CEN
standard EN 474-3 is given as a percentage of the tipping load.
The percentage values, which must not be exceeded, are as fol-
lows:

Uneven ground: 60 % of tipping load

Firm and even ground: 80 % of tipping load

It must be possible to control and handle the load hydraulically in

all likely positions at the same time as all other hydraulic circuits
are actuated. The maximum permissible load capacity is either de-
L67323A termined by the stability or the hydraulic capacity of the machine
whichever is less.
In countries outside the EU/EEA other regulations may apply.
Therefore, always check which local rules apply.
 Operating techniques
100 Material handling arm

Material handling arm

IMPORTANT! Only a material handling arm approved by
Volvo CE for use with the machine, may be used.
Maximum permissible load for the machine using a material han-
dling arm is shown in an "Operating Load Table" on the attach-
ment. Do not exceed the given limits.
The rated operating load capacity given applies when the machine
is operated on firm and level ground and is, at the most, half of the
tipping load. When operating on uneven ground, the load must be
adapted to the ground conditions.
A mounting check must be carried out every time the attachment
has been mounted to check that the attachment is locked.
Check that the attachment is locked by pressing it against the
L64256A ground.
In certain countries it is a legal requirement that regular checks are
carried out by an authorised person, who should also keep a spe-
cial inspection diary over these checks.

Positioning of machine
It is important that the ground where the machine is to be placed
is level and firm. If the ground is soft, call the management so that
necessary action can be taken.

Loading
3 Apply the load table to the actual extension of the material han-
dling arm.
3 Make sure that the pressure in the front tyres are according to
the recommendations, if the maximum permissible load is uti-
lised frequently.
Do not lift until you know:
– where the load is to go.
– that it can be placed there.
– that the correct lifting device is used (wire, chain, etc.).
– that the sling is connected to the load in a correct way.
– that you have been given the signal to lift, if a signal man is as-
sisting.
NOTE: The material handling arm must not be used for a
heavier load than has been specified for the particular arm ex-
tension.

WARNING!
The moving or lifting of personnel with the aid of the mate-
rial handling arm is not permitted – risk of injuries.
 Operating techniques
Material handling arm 101

Operating with material handling arm

3 Remember that a small movement at the attachment bracket
becomes a large movement at the outer end of the material
handling arm.
3 Operate the machine and the material handling arm with gentle
and careful movements, so that the load does not start to
swing.
3 Never exceed the maximum permissible load of the material
L64257A handling arm.
A load table is displayed on one side of the attachment itself.
3 When transporting on, for example, a public road, the material
handling arm should be fully retracted and the front end should
be tilted rearward.
3 Extending or shortening the arm length should be done manu-
ally (be aware of the risk of pinching).
NOTE: If the length of the material handling arm has been
changed, check that the pins at the ends of the respective
sections have been locked in a secure way (special locking
pins).
3 Only use lifting attachments which are approved and which do
not overload the machine.

Operating with a load

WARNING!
Remember that the stability of the machine when straight is
reduced when turning.

3 When moving with a suspended load, keep the material han-

dling arm as low as possible. The speed should be limited to
6 km/h (3.7 mph).
3 Use slings to stabilise and to prevent the load from swinging.
3 A lift should not be carried out when the force of the wind and
the bulk of the load are such that the load cannot be handled
with safety.
3 Keep your eyes on the load at all times. If, at any time, you can-
not see the load, a signal man must be called in before starting
the job. (See page 103).
3 Operate the material handling arm as smoothly as possible.
3 Do not move a load above persons, office and personnel huts.
L64258A
3 Under no circumstances should the material handling arm be
used for pulling up boards or planks which have been nailed
down. Pulling obliquely must not be done.

Suitable gear: Gear selector in position 4.

Mode selector: Position LIGHT or HEAVY
Boom Suspension System: Gear-dependent position or
not activated
 Operating techniques
102 Rotating attachments

Rotating attachments
Hydraulically powered, rotating attach-
ments

WARNING!
A machine with a hydraulically powered attachment must
be provided with an emergency stopping device inside the
cab. The stopping device turns off the power to the attach-
ment and stops its movement.

If the machine is used with hydraulically powered, rotating working

parts, e.g. brush, bush clearer, sand spreader, the following gen-
eral safety rules must be followed:
3 The fitting of such attachment for the first time must only be
done by a trained person.
3 Read, understand and follow the instructions supplied with the
attachment.
3 Always stop (turn off the hydraulic supply) the rotating/moving
part of the attachment before you leave the cab.
3 When servicing or maintaining the attachment or in case of the
working parts having come to a standstill while operating, the
hydraulic hoses to the attachment must be disconnected in or-
der to prevent accidental engagement of the hydraulic power,
which might result in an accident.

Check that the attachment in question is CE marked, if the attach-

ment is not made by Volvo CE.
Make sure that the dealer has written the attachment into the "Dec-
laration of Conformity" for your machine as being an approved at-
tachment.

WARNING!
To avoid accidents, always find out from the manufacturer
what instructions for safe handling apply BEFORE you fit
and start using an hydraulically powered attachment.
 Operating techniques
Signalling diagram 103

Signalling diagram
If the operator's view is restricted because of, for example, an
obscuring load, a signal man must be used.
The faster lifting or lowering movements required or the faster the
machine should move, the more lively should the signal man's
movements be carried out. If two or more operators make use of
the same signal man, there should be an agreement beforehand
how the lift should be carried out and how the signals should be
given to the respective operator.

L67279A

L67281A1

L67280A

START STOP END

Both arms are extended horizon- Right arm pointing upward with the Both hands are clasped at chest
tally with the palms facing forward palm facing forward height

L67283A

L67278A

L67282A

RAISE LOWER VERTICAL DISTANCE

Right arm pointing upward with the Right arm pointing downward with The hands indicate the relevant
palm facing forward and the hand the palm facing forward and the distance
slowly making a circle hand slowly making a circle

L67284A
L67277A L67285A

MOVE FORWARD MOVE REARWARD DANGER (EMERGENCY STOP)

Both arms bent with the palms Both arms bent with the palms Both arms pointing upward with the
turned upward and the forearms turned downward and the forearms palms facing forward
slowly moving toward the body slowly moving downward away
several times from the body several times
 Operating techniques
104 Signalling diagram

L67286A
L67287A L67288A

OPERATE IN INDICATED DIREC- OPERATE IN INDICATED DIREC- HORIZONTAL DISTANCE

TION TION The hands indicate the relevant
The arm extended horizontally with The arm extended horizontally with distance
the palm facing downward and the the palm facing downward and the
arm making small slow movements arm making small slow movements
to the right to the left

Slinging
Boards, planks, reinforcing irons or similar should have the sling
arranged so that they cannot fall out.

When lifting girders, a pair of girder scissors should preferably be

used.

Place for example cut-up air hoses between the sling and sharp
edges.

L64488A
The sling should be well tightened.
 Operating techniques
Signalling diagram 105

Lifting attachments
Lifting equipment, such as chain, load platform, lifting fork and
clamping scissors, must:
3 be clearly marked with information about the highest permissi-
ble load.
3 correspond to the rules about dimensions which apply accord-
ing to local and/or national regulations.
Regarding regular checks, see the text below.

WARNING!
Never attach a lifting device (chain, sling or similar) around
the teeth on the bucket when lifting. If a tooth should break,
there is a risk of serious injury.

Running checks of lifting attachments

Continuous supervision should be carried out at regular intervals
by a knowledgeable and experienced person and arranged by the
employer. Should wear, cracks or other deficiencies, which may
jeopardise the safety of the machine or the lifting equipment, be
noticed during the running checks, the machine or the lifting equip-
ment must not be used.

Other attachments
3 Attachments which are only used for specific purposes often
have special safety instructions. Never start operating with a
special attachment, without first having found out which regula-
tions apply.
3 Find out how the attachments should be fitted and used and
that they are approved for use with your machine (according to
the Declaration of Conformity).
 Operating techniques
106 Getting stuck

Getting stuck
What to do if the machine gets stuck
If the machine has got stuck, it is usually best to reverse out. If you
cannot reverse or drive forward, try the following:
1 Engage the differential lock with the foot switch.
2 Select a low gear (1st or 2nd).
3 Reverse and steer the machine fully to the left and then to the
right alternately (like a duck's waddle).

L64411A
If only the front wheels have got stuck proceed in either of the fol-
lowing ways:
1 Lift the front wheels, supporting the machine on the bottom of
a flat bucket and reverse.
2 Steer to the right or to the left, press the bucket against the
ground, lift up the front wheels and steer the other way, raise
the bucket slightly and reverse.
3 Lift up the front wheels using the bucket. Manually fill the holes
under the wheels with branches, pieces of wood or similar and
reverse.
4 If the machine needs to be recovered, see page 81.

You must never engage the differential lock when one of the
wheels is slipping. Lower the engine speed until the wheel
has stopped. Then engage the differential lock.
 Safety when servicing
Service position 107

Safety when servicing

This section deals with the safety rules which must be followed
when checking and servicing the machine. Volvo CE disclaim all
responsibility if other tools, lifting devices or working methods are
used than those described in this publication.
L68293A
Further safety rules and warning texts are given within the respec-
tive sections.
NOTE: Lifting with a jack must only be carried out by trained
personnel.

WARNING! Service position

If work has to be carried out on the BEFORE you begin service work the machine must be placed
machine before it has cooled down, on level ground and prepared as shown below.
care must be observed with regard to AFTER you have completed the service, any guard plates must
hot liquids and hot machine parts – be re-installed and all engine covers are to be closed and locked.
risk of burns.
2 4
3

5
P ! 8

L61721C

6 7

1 The attachment should be resting on the ground. 5 Attach a black and yellow label to the steering
wheel.
2 Apply the parking brake. 6 Connect the frame joint lock.
3 Stop the engine and take out the ignition key. 7 Block the wheels in a suitable way (with, for exam-
(Does not apply when checking oil level in trans- ple, wedges).
mission).
4 Carefully release the pressure in pressure lines 8 Allow the machine to cool.
and pressure vessels to avoid risks.
 Safety when servicing
108 Before service read

Before service read

3 Read the Operator's Manual and the plates and instructions
found on the machine to obtain the required knowledge and in-
formation about the machine.
3 To be able to carry out the service work in a correct way, it is
important that you use the correct tools and equipment. Re-
place or repair broken tools and faulty equipment.
3 When lifting the machine, the frame joint must be locked and
the machine lifted at the eyes intended for this purpose, see
page 84.
3 Use a hard hat, safety glasses, protective shoes and gloves
and an approved respirator or other protective articles when re-
quired.
3 Do not wear loose-fitting clothing or jewellery.
L50385B
3 Keep service surfaces and handholds clean from oil, dirt and
ice.
3 Use the stepping areas provided to avoid the risk of slipping.
3 Make sure that there is sufficient ventilation when starting the
engine indoors.
3 Do not exceed the maximum permissible floor load.
3 Do not stand in front of or behind the machine while the engine
is running.
3 Use a ladder when changing light bulbs or carrying out other
service work high up on the machine.
3 Use a long-handled window scraper and brush or a ladder
L64527A
when cleaning the outside of the windows.

L67303B
Stepping surfaces, L150E

L67303C
Stepping surfaces, L180E
 Safety when servicing
Before service read 109

3 The installation of two-way radio, mobile telephone, lever steer-

ing or similar equipment must be carried out by a skilled per-
son, as faulty installation may cause interference with the
electronic components controlling vital machine functions.
3 If service work has to be carried out under raised lifting arms,
these must first be secured (lifting arm support). In addition, the
control lever lockout should be engaged and the parking brake
applied.
3 Take care when changing oil in engine, hydraulic system or
transmission as the oil may be hot and cause burns.
3 When emptying/draining oil or fuel, use a pump or a hose and
collect the liquids in a suitable vessel. Spillage will damage the
environment and may cause a fire. Waste oil and other contam-
inating liquids should be taken care of by a firm especially au-
thorised to carry out such work.
3 When operating in an area which is contaminated or dangerous
to one's health, the machine must be especially equipped for
this purpose. Special local safety regulations apply within such
areas and also when servicing the machine.
3 Stop the engine before opening engine covers etc. Make sure
that no tools or other objects, which may cause damage, have
been forgotten in or on the machine.
3 Check that the equipment you are using for lifting or supporting
parts of the machine, e.g. strops, slings, ratchet blocks and
ground support, safely can cope with the strain they are ex-
posed to and meet applicable national regulations.
3 Release the pressure in pressure vessels, components and
systems carefully and in the prescribed way, so that the excess
pressure is released without risk.
3 When connecting hydraulic hoses, check that the desired effect
has been achieved, that is, check that the hydraulic function op-
erates in the expected way, see page 96.
3 Hoses, pipes and quick-action couplings may be pressurised
even if the machine is stationary and the engine turned off.
Such pipes and hoses should therefore only be disconnected
by trained personnel.
3 When looking for leaks, use a piece of paper or wood, not your
hand.
 Safety when servicing
110 Before service read

Fire prevention measures

There is always a risk of fire. It is important that you use a fire ex-
tinguisher that suits your machine and working environment and
that you learn how to use it. The fire extinguisher should be placed
under the seat bracket or externally in a lockable box.
If the machine is to be provided with a hand-held fire extinguisher,
it should be of the ABE type (ABC in the USA), which means that
it is possible to extinguish fires in both solid and liquid carbona-
ceous material and that the active compound does not conduct
electricity.
L59853B

The effectiveness grade I means that the time the extinguisher is

effective must not be less that 8 seconds, grade II at least 11 sec-
onds and grade III at least 15 seconds.
A hand-held fire extinguisher ABE I (in the USA ABC type) normal-
ly corresponds to a powder content of 4 kg (8.8 lb) (EN-grade
13A89BC), the EN 3-1995 standard, parts 1, 2, 4 and 5.

At the slightest sign of fire, and if the situation allows, take the fol-
lowing steps:
1 Drive the machine away from the fire-sensitive area caused by
the fire.
2 Lower the lifting arms to the ground.
3 Stop the engine by turning the ignition key to the "0" position.
4 Leave the cab.
5 Turn off the battery disconnect switch.
6 Start putting out the fire and notify the fire brigade/department
if necessary.

3 It is forbidden to smoke or have an open flame near a machine

when filling with fuel or when the fuel system has been opened
and in contact with the surrounding air.
3 Diesel fuel oil is flammable and must not be used for cleaning.
Use an approved solvent and do not inhale the fumes. Also
bear in mind that certain solvents can cause skin rashes and
constitute a fire hazard.
3 Store flammable starting aids in cool, well ventilated locations.
These aids must not be used in connection with electric pre-
heating of the induction air.
3 Keep the place clean where the service is to be carried out. Oil
or water makes the floor slippery and is also dangerous in con-
nection with electrical equipment or electrically powered tools.
Oily or greasy clothes are a serious fire hazard.
 Safety when servicing
Before service read 111

3 Check daily that the machine and the equipment, e.g. under-
body plates are free from dust and oil. In this way the risk of fire
is reduced and it is easier to detect faulty or loose components.
NOTE: If a high-pressure jet is used for cleaning, take great
care as the insulation of electric leads can be damaged even
at a moderately high pressure and temperature.
Protect electrical leads in an appropriate way.

3 Take extra care when cleaning the machine after it has been
used in a fire-sensitive environment, e.g. saw-mill and refuse
dumps. Reduce the risk of spontaneous combustion by install-
ing for example silencer guard or high-capacity cyclone pre-
cleaner.
3 Sound absorbing material in the engine compartment must be
kept clean to minimise the fire hazard.
3 Fire prevention equipment which is installed on the machine
must be maintained and regarded as a complement to the ac-
tions of the operator in case of a fire.
3 Check that fuel lines, hydraulic and brake hoses and electrical
cables have not been damaged by chafing or are not in danger
of being damaged in that way because of incorrect installation
or clamping. This applies particularly to unfused cables, which
are red and marked R (B+) and routed:
– between the batteries
– between battery and starter motor
– between alternator and starter motor
– to the preheating element on the engine
Electrical cables must not lie directly against oil or fuel lines.
3 The following applies for welding and grinding work:
– A fire extinguisher should be kept near to hand.
– The ventilation must be good when working indoors.
– Approved respirator should be used
– The work surface must be cleaned.
– Do not weld or grind on components which are filled with
flammable liquids, e.g. tanks and hydraulic pipes. Exer-
cise care with such work in the proximity of these places.
 Safety when servicing
112 Before service read

Working on painted surfaces

When welding, grinding and gas cutting, the paint finish must first
be removed from an area with a radius of at least 10 cm (4 in) from
the point where the work is to be carried out. The reason for this is
that paint when heated gives off a great number of different sub-
stances which can cause irritation and be very harmful to a per-
son's health in case of long or frequent exposure.
In addition to the health hazard, the weld will also be of inferior
quality and strength, which in the future may cause the weld to
break. Therefore, never weld directly on a painted surface.

Methods and precautionary measures when

removing paint:
3 Blasting
– use respirator and eye protection
3 Paint remover or other chemicals
– use a portable air extractor, respirator and protective
gloves
3 Grinding machine
– use a portable air extractor, respirator and protective
gloves and eye protection

Fluor rubber
Observe extra great care when it is suspected that you may have
to handle fluor rubber.
Certain seals which have to withstand high operating temperatures
(e.g. in engines, transmissions, axles, hydraulic motors and
pumps) may be made from fluor rubber, which, when exposed to
strong heat (fire), forms hydrogen fluoride and hydrofluoric acid.
This acid is very corrosive and cannot be rinsed or washed off from
the skin. It causes very severe burns which take a long time to
heal.
It usually means that damaged tissue must be surgically removed.
Several hours may pass after contact with the acid, before any
symptoms appear and therefore one is not given any immediate
warning. The acid may remain on the machine parts for several
years after a fire.
If swelling, redness or a stinging feeling appears and one suspects
that the cause may be contact with heated fluor rubber, contact a
medical doctor immediately. If a machine, or part of a machine, has
been exposed to fire or severe heat, it should be handled by spe-
cially trained personnel. In all handling of machines after a fire,
thick rubber gloves and effective goggles must be used.
The area around a part which has been very hot and which may be
made of fluor rubber should be decontaminated by thorough and
ample washing with lime water (a solution or suspension of calci-
um hydroxide, i.e. slaked lime in water). After the work has been
completed, the gloves should be washed in lime water and then
discarded.
 Safety when servicing
Before service read 113

Rubber and plastics

Polymer materials can, when heated, form compounds which are
dangerous to health and environment and must therefore never be
burned when scrapped. Also take care when handling machines
which have been subjected to fire or other extreme heat.
If gas cutting or welding is to be carried out near such materials,
the following safety instructions must be followed:
– Protect the material from heat.
– Use protective gloves, protective goggles and an approved res-
pirator.

Waste hazardous to the environment

3 Painted parts or parts made of plastic or rubber which are to be
scrapped must never be burnt, but must be taken care of by an
approved refuse-handling plant.
3 Batteries, plastic objects and anything else which is suspected
of being dangerous to the environment must be taken care of
in an environmentally safe way.

Check-list after fire

When handling a machine which has been damaged by fire or
been exposed to intense heat, the following protective meas-
ures must under all circumstances be followed:
3 Use thick, gloves made of rubber and wear goggles which are
certain to protect your eyes.
3 Never touch burnt components with your bare hands, as there
is a risk that you may come into contact with melted polymer
materials. First wash thoroughly with plenty of lime water (a so-
lution or suspension of calcium hydroxide, i.e. slaked lime in
water).
3 As a precaution, seals (O-rings and other oil seals) should al-
ways be handled as if they were made of fluor rubber.
3 Treat skin, which is suspected of having come into contact with
burnt fluor rubber, with Hydrofluoric Acid Burn Jelly or some-
thing similar. Seek medical advice. Symptom may not appear
until several hours afterwards.

3 Discard gloves, rags etc. which are suspected of having come

into contact with burnt fluor rubber.
 Safety when servicing
114
 Basic preventive maintenance
115

Basic preventive mainte-

nance
For the machine to function satisfactorily and at lowest possible
cost, a thorough maintenance is required. This section of the man-
ual describes the maintenance work which the operator can carry
out.If certain operations require trained workshop personnel and
special equipment, this will be indicated.
The intervals recommended between checks, oil changes and lu-
brication apply provided that the machine is used under normal en-
vironmental and operating conditions. See "Lubrication and
service chart", on pages 154 and 158 respectively.

L52168B

Arrival and Delivery Inspection

Before the machine leaves the factory, it is tested and adjusted.
The dealer must also, if the warranty is to apply, carry out "Arrival
and delivery inspections" according to applicable form, which must
be signed.

Delivery Instructions
When handing the machine over, the dealer must give the buyer
SERVICE PROGRAMME
Machine type

Owner
Ser. no. Operated hours Delivery date

Date
"Delivery instructions" according to applicable form, which must be
Wheel Loaders
Excavator-Loaders
Dealer

Machine type
Sign.

. Ser. no.
signed, if the warranty is to apply.
Please pay attention to the safety instruction in the Operator’s Manual and Service Manual for the
Owner Customer no.
machines concerned.
DELIVERY INSTRUCTIONS
See Service Guide regarding specifications and the Operator ’s Manual regarding information about controls and changes.
Delivery instruction carried out on the
Wheel loaders / Operator (Recipient).

OPERATING HOURS / HOURLY INTERVAL

Excavator loadersFirst First Daily every every every every every Notes
100 1000 50 250 500 1000 2000
Articulated haulers
A = Warranty Inspections
B = Maintenance

1
1:1
General
Test-run and check.
Excavators
A A B B B B B B

Pay attention to the safety instruction in the Operator’s Instruction Dealer

ARRIVAL AND DELIVERY
Manual
Mashine type Ser. No. Running hours Arrival date

Dlivery date
Service Programmes
– Starting and stop functions
cold-starting devices).
(includingand
Performing
1 Check
INSPECTON
anysigning the delivery instructions is a pre-condition for a validArrival
machine warranty.
inspection
together with the owner/operator that the delivered machine corresponds to the order.
by Performed Delivery inspection by

– Instruments, lights, direction indicators,

Wheel Loaders /

Warranty Inspection
reflectors, hazard flashers, wipers, was-
hers and horn, if applicable2 Presentation Excavator
– reversing of the machine including Loaders
optional equipment.
alarm. Articulated Haulers
– Gear selector pos. / automatic gear shif- Excavators
ting. Review of the Operator ’s Manual with emphasis on the following points.
– Differential lock, if fitted.(Depending on machine type, certain points are omitted.) Performed
– Brake system (service brakes). Please pay attention to the safety instructions in the Operator’s and Service Manuals concerned.
– Control lamp for low brake 3 Operation
pressure.
– Parking brake. – Run-in instructions.

Two Warranty Inspections should be carried out if the warranties

Arrival inspection Performed
– Steering system.
– Heating and ventilation, fan– Instruments
and controlsand operating controls.
1 The arrival inspection is the first check of the product after transport. Any deviations or transport
incl. any air conditioning. damage must be reported to the carrier, and then immediate corrective actions must be taken.
– Start-stop, warming up.
– Loader unit / excavator unit functions
incl. boom kick-out and bucket positions. shifting gears.
– Transmission, 2 Check that the machine is equipped according to the order confirmation, and that tools and man-

1:2
– Optional equipment

– Engine mounting
– Transmission mounting
– Retarder function.
Bolted joints, checking tightening torque:
– Service brakes and parking brake.
– Steering, secondary steering.
3
uals are supplied with the machine. Any deviations should be reported to the sales department.

Check that no caps for the oil filler pipe, fuel tank, radiator or expansion tank are missing.
When applicable, check that the cap for the brake fluid reservoir is not missing.
are to apply. The first within 100 operating hours and the second
at the latest at 1000 operating hours.
– Axle mounting 4 Machines transported by ship should be hosed down with fresh water as soon as possible.
– – Operator environment, heating, ventilation and air conditioning.
Flanged joints, propeller shafts 5 After the inspection, the anti-corrosion treatment of the machine should be renewed, if it is to be
– Support bearing, propeller –shaft stored again for a longer period. Follow the instructions in "MAINTENANCE OF IN-STOCK
Attachment bracket (attaching an attachment).
– Cab mounting MACHINES".
– – Loading,
Roll Over Protective Structure, ROPS,digging, dumping and lifting operations.
only L330C and L330D. Delivery inspection Performed
– Operation on a public road.
1:3

1:4
Lubrication, see lubrication chart.
–
every 100 hours, see Operator’s

Leakage, check.
Towing.
Certain points should also be lubricated
Manual.
4 Service,
Engine.
maintenance
6 Check the engine coolant level and the oil level in the engine, transmission and hydraulic system.
When applicable, check the level in all brake fluid reservoirs.
7 Remove transport protection from the hydraulic cylinders.
Clean any anti-corrosion agent from the piston rods.
The carrying out of these inspections is a condition for the warranty
1:5 Pipes and hoses, check.
Electrical system.
Power transmission.
8 system.
– Lubrication, cooling system and fuel Check and adjust the tire pressure.

9 Start the engine and run the machine until normal operating temperature has been reached.
Check that the following systems function normally:
– Electrical system: Check that instruments and lights work.
to apply.
– Brake system: Apply the service brakes and engage the retarder (optional).
Brake system.
– Steering system: Turn the steering wheel to both left and right steering lock positions.

Condition Test
Compressed air system. – Hydraulic system: Run all hydraulic cylinders to their respective end position.
Check the function of all equipment. 1 (8)
Hydraulic system.
10 Check that there are no leaks.
Lubrication chart.
11 Any malfunctions or defects must be corrected, noted and reported to the supervisor.
5 Safety instructions. See page 2.

1 (2)
Condition Test is carried out at authorised dealer workshops and
provides information about the general condition of the machine.
1 (2)

L68941A
 Basic preventive maintenance
116 Service points, L150E

Service points, L150E

+ –

+ –

1 Level sight glass, hydraulic oil 18 Breather filter, fuel system

2 Transmission, breather filter 19 Breather filter, rear axle
3 Air cleaner 20 Filling point for hydraulic oil and return oil filters,
hydraulic system
4 Air filter intake 21 Ventilation filters, cab
5 Expansion tank 22 Breather filter, front axle
6 Filling point for transmission oil 23 Battery
7 Level sight glass, transmission oil 24 Alternator belt
8 Draining, hydraulic oil 25 Filling point for engine oil
9 Full-flow filter, engine 26 Oil dipstick, engine
10 Engine oil cooler 27 Secondary fuel filters
11 Part-flow filter, engine 28 Draining, engine oil and coolant
12 Filter, coolant 29 Draining, coolant
13 Primary fuel filter and water trap 30 Draining, hydraulic oil
14 Battery 31 Suction strainer, transmission
15 Filler, fuel 32 Oil filter, transmission
16 Battery disconnect switch 33 Filter, axle oil cooling, front axle (optional equip-
ment)
17 Filter, axle oil cooling, rear axle (optional equip-
ment)
 Basic preventive maintenance
Service points, L180E 117

Service points, L180E

+ –

+ –

1 Level sight glass, hydraulic oil 18 Breather filter, rear axle

2 Transmission, breather filter 19 Filling point for hydraulic oil and return oil filters,
hydraulic system
3 Air filter intake 20 Ventilation filters, cab
4 Expansion tank 21 Breather filter, front axle
5 Filling point for transmission oil 22 Battery
6 Level sight glass, transmission oil 23 Alternator belt
7 Draining, hydraulic oil 24 Filling point for engine oil
8 Draining, coolant 25 Oil dipstick, engine
9 Full-flow filter, engine 26 Secondary fuel filters
10 Part-flow filter, engine 27 Draining, engine oil and coolant
11 Filter, coolant 28 Draining, hydraulic oil
12 Battery 29 Filter, axle oil cooling, rear axle (optional equip-
ment)
13 Filler, fuel 30 Suction strainer, transmission
14 Battery disconnect switch 31 Oil filter, transmission
15 Primary fuel filter and water trap 32 Filter, axle oil cooling, front axle (op. equipment)
16 Breather filter, fuel system
17 Air cleaner
 Basic preventive maintenance
118 Engine
Max. Min. Engine
Engine oil, checking
L68326A
Check the oil level every 50 hours.
3 When checking the machine should stand on level ground.
3 The check should be carried out when the oil is cold and has
had time to run down to the bottom of the sump.
The level should be between the marks on the oil dipstick.
A
Engine oil, changing
B Change oil every 500 hours.
The conditions for the 500 hour interval between oil changes are
that:
– the oil filters are replaced every time the oil is changed.
L68325B – the oil filters are Volvo original “Long Life” filters and “By-pass”
L150E filters.
A Oil dipstick – the diesel fuel sulphur content does not exceed 0.3 % by
B Filler pipe weight.
– the oil is of a certain quality grade, see page 167.
MAX MIN – the correct oil viscosity for the ambient air temperature is se-
lected according to diagram, see page 167.
If any of these conditions are not met, the oil should be changed
L67713A
and the filters replaced every 250 hours.
B More frequent changes and replacements may be necessary for
example during severe operation (high fuel consumption). This is
monitored via the engine control unit and alarm text is shown on
the display unit.
If the engine fuel sulphur content exceeds 0.5 percent by weight or
if the oil grade is below ACEA-E3 or API CE the oil should be
changed every 125 hours.
The oil must be changed at least every sixth month, regardless
of the number of operated hours.

Draining
A
L67714A

L180E Drain the oil while the engine is still warm.

A Oil dipstick 1 Loosen the cover at the inside of the rear wheel and swing the
B Filler pipe cover to one side.
2 Unscrew the protective cover for draining engine oil (lower
draining point).
3 Place one end of the hose (the hose lies in the battery box) in
a suitable vessel and screw the other end onto the draining
point.

Take care of waste oil and liquids in an environmentally safe

way!

Filling
Fill with oil through the filler pipe.
Oil capacity when changing:
L150E, approx. 39.5 litres (10.4 US gal) including filters.
L63480B

L180E, approx. 48 litres (12.7 US gal) including filters.

Draining engine oil
NOTE: To remove the alarm text “INFO Min. Engine Oil Level”
the engine must be turned off for ten minutes.
For oil quality grades, see page 167.
 Basic preventive maintenance
Engine 119

B A Engine oil filters, replacing

Replace the oil filters every time the oil is changed.
The oil filters are of the disposable type, i.e. they cannot be
cleaned, but must be replaced.

3 Removing
– Use a filter clamp and turn clockwise.

3 Installing
– Fill the filters with oil and apply oil to the gasket.
L68998A
Engine oil filters, L150E
– Screw on the filters until the gasket just touches the seal-
ing surface. Then tighten a further half of a turn by hand.
A Part-flow filter
B Full-flow filters
– Start the engine and check that the gaskets seal. If they
do not, remove the filters and check the sealing surface.
Usually it does not help to tighten harder.

A
NOTE: After replacing oil filters, the engine must run at low
idling for at least one minute to make sure that the engine is
lubricated before the machine is put to work.

B
L67715A
Engine oil filters, L180E
A Part-flow filter
B Full-flow filters

IMPORTANT! It is important that the filters are filled with oil

before they are installed. This is to ensure lubrication of the
engine immediately it is started.
 Basic preventive maintenance
120 Fuel system

Fuel system
Fuel tank
Clean fuel is essential for trouble-free running of the diesel engine.
3 Carefully clean around the filler cap before removing it.
3 Avoid spillage when filling. Spilt fuel attracts dirt and is a fire
hazard if it is spilt on hot surfaces.
3 During the cold season keep the fuel tank full to prevent water
condensing in the tank.
L67709A 3 When required, remove the plug at the bottom of the fuel tank
Fuel tank cap and drain off any sludge.
Fuel tank capacity: 370 litres (97.7 US gal)
For fuel quality, see page 167.

A Fuel filters
Replace fuel filters every 1000 hours.
Take care of fuel spillage by collecting it in a suitable vessel.
The fuel filters consist of a primary fuel filter integrated with the wa-
ter trap and a secondary fuel filter. On the secondary fuel filter
there is a hand pump which is used when bleeding the system. On
the L150E the hand pump is positioned behind the filter. The pri-
mary fuel filter works as a prefilter for the feed pump.
When installing the filters, they should only be tightened by hand.
B The filter insert should be replaced by service personnel at an au-
L67730A thorised dealer workshop.
A Primary fuel filter (on L150E the filter is po- After filter replacement the fuel system must be bled.
sitioned on the left side of the machine) The way the fuel flows is:
B Secondary fuel filters
L150E
tank – primary fuel filter with water trap – feed pump – secondary
fuel filter – injection pump – injectors – cylinders
L180E
tank – primary fuel filter with water trap – feed pump – secondary
fuel filter – unit injectors – cylinders
 Basic preventive maintenance
Fuel system 121

Fuel system, air bleeding, L150E

A B Take care of fuel spillage by using a vessel or a plastic hose.
Air bleeding is done in three steps:
Step 1
– Turn the ignition key to running position (1).
– Loosen bleeder screw (B) on the primary filter head.
– Pump with hand pump (A) on the primary filter head until fuel
free from air flows out.
– Tighten the bleeder screw.

L67712A

A Hand pump on primary filter head

B Bleeder screw on primary filter head

C Step 2
– Loosen bleeder screw (D) on the secondary filter head.
– Pump with hand pump (A) behind the filter until fuel free from
air flows out.
– Tighten the bleeder screw.

D
L69002A

C Hand pump on secondary filter head

D Bleeder screw on secondary filter head
Step 3
– Slacken the bleeder screw on the injection pump and pump
with the hand pump (C) until fuel free from air flows out.
– Tighten the screw. If there is a leakage, the copper gaskets
should be replaced.
– Start the engine and leave it running at slightly above low idling
for approx. 10 minutes to purge the system of any remaining
air.

L68572A

Bleeder screw on injection pump

 Basic preventive maintenance
122 Fuel system

Fuel system, air bleeding, L180E

A B
Take care of fuel spillage by using a vessel or a plastic hose.
Air bleeding is done in three steps:
Step 1
– Turn the ignition key to running position (1).
– Loosen bleeder screw (B) on the primary filter head.
– Pump with hand pump (A) on the primary filter head until fuel
free from air flows out.
– Tighten the bleeder screw.

L67712A

A Hand pump on primary filter head

B Bleeder screw on primary filter head
Step 2
– Loosen bleeder screw (D) on the secondary filter head.
– Pump with hand pump (C) on the secondary filter head until fuel
free from air flows out.
C – Tighten the bleeder screw.

L67711B

C Hand pump on secondary filter head

D Bleeder screw on secondary filter head
Step 3
– Open the bleeder screw by the cylinder head and pump with
the hand pump on the secondary filter head until fuel free from
air flows out.
– Tighten the bleeder screw.
– Start the engine and leave it running at slightly above low idling
for approx. 10 minutes to purge the system of any remaining
air.
Check that there are no leaks.

L67728B

Bleeder screw by cylinder head

 Basic preventive maintenance
Fuel system 123

A Water trap
Take care of fuel spillage by using a vessel or a plastic hose.
Drain the water trap every 250 hours.
Draining water from the fuel has to be done by hand.
A non-return valve in the filter head prevents the fuel from running
back to the tank. As no fuel can run back, the pressure will remain
B and as a consequence no water will be drained unless new fuel is
C pumped in.
D
Proceed as follows:
L67729B – Place the end of the hose in a vessel.
A Hand pump on primary filter head – Slacken draining nipple (C).
B Water trap – Pump with hand pump (A) on the primary filter head until all wa-
C Draining nipple ter has been forced out of water trap (B).
D Hose – Tighten the draining nipple.

Take care of waste oil and liquids in an environmentally safe

way!

Breather filter, fuel system

Replace the filter every 2000 hours.

L67710B

Breather filter, fuel system

 Basic preventive maintenance
124 Turbocharger

Turbocharger
The turbocharger is lubricated and cooled through the engine lu-
brication system.

L66718A
Important for the function of the turbocharger is that:
Air Lubricating oil Exhaust
3 lubrication and cooling is safeguarded by
– not racing the engine immediately after it has been start-
ed.
– the engine is allowed to run at low idling for a couple of
minutes before it is turned off.
3 engine oil is changed and oil filters are replaced at prescribed
D intervals.
A C 3 the air cleaner is serviced regularly and that the exhaust sys-
tem and lubricating oil lines do not leak.
B
In case jarring noises can be heard, or if the turbocharger vibrates,
L67289A
it must be reconditioned or replaced immediately.

A Exhaust inlet
B To exhaust system Only authorised dealer workshops should carry out work on
the turbocharger.
C CAir inlet
D Compressed air
 Basic preventive maintenance
Air cleaner 125

Air cleaner
Engine, air cleaner
The degree of engine wear depends largely on the cleanliness of
the induction air. The air cleaner prevents dust and other impurities
from entering the engine. Therefore, it is very important that the air
cleaner should be checked regularly and maintained correctly.

L68328A

Air cleaner, L150E

Primary filter, maintenance and replace-

ment
When the alarm text "Clogged Engine Air Filter" is shown or
every 1000 hours, the filter should be replaced or be cleaned.
The period of operation between filter replacements vary de-
pending on the working environment of the machine. In cer-
L68329A tain environments the filter needs to be replaced often.
3 The filter can be cleaned according to instructions which per-
sonnel at your authorised dealer workshop will give you. How-
Air cleaner, L180E ever, after the filter has been cleaned five times or if it is
damaged, it must be replaced.
NOTE: Make a mark on the decal at the end of the secondary
filter every time the primary filter is replaced or cleaned.
3 In connection with replacing the filter, the cover for the air
cleaner should also be cleaned as this works as a container for
particles which have not been trapped in the filter.
3 Check that all hose and pipe connections from the air cleaner
to the engine induction manifold are tight. Check-tighten hose
clips.
3 If the alarm text remains after replacing the primary filter, also
the secondary filter must be replaced.

L67731B
Do not, under any circumstances, run the engine without a fil-
Primary filter ter or with a damaged one.
Always have a spare filter at hand and keep the filter well pro-
tected from dirt.

Secondary filter
Replace the filter every 2000 hours or when the main filter has
been replaced three times.
The filter cannot be cleaned, but must be replaced.
The secondary filter works as a protective filter if the main filter is
damaged.
L67732B

Secondary filter
Never remove the secondary filter unless it is to be replaced.
 Basic preventive maintenance
126 Oil-bath precleaner (optional equipment)

Oil-bath precleaner (optional equip-

ment)
When working in a particularly dusty environment, we recommend
that an oil-bath precleaner should be installed in series with the ex-
isting dry-filter air cleaner. This will provide further safety against
damage to the engine.
The particle-retaining ability of the oil-bath cleaner is between 90
and 95 %, which in practice, means that the standard dry-filter air
cleaner will act as a secondary filter, with a replacement interval
which is twice as long, i.e. 2000 hours.

Check the oil level daily. Oil capacity, 9.5 litres (2.5 US gal).
L66719A
3 Change oil and clean the lower and upper steel mesh filters if:
Oil-bath precleaner
– the oil is dirty and viscous.
– there are sludge deposits or dry spots on the underside of
the lower steel mesh filter.
3 The oil bowl, the lower and upper steel mesh filters should be
washed in diesel fuel.
3 Avoid using petrol (gasoline) for cleaning, as any remaining
petrol can cause the engine to surge when it is started later.
3 When filling or changing oil use oil with the same viscosity as in
the engine.

Clean the steel mesh filters inserts every 2000 hours.

Washer fluid reservoir, front and rear win-

dows
3 Make sure that there is sufficient anti-freeze in the washer fluid
when there is a risk of frost.
3 Top up when necessary.
3 Make sure that the cap on the reservoir is securely tightened
and that the reservoir is clean on the outside. A smell of fluid
may otherwise spread to the cab.

L66594B

Washer reservoir
 Basic preventive maintenance
Cooling system 127

Cooling system
For the cooling system to function without problems, the coolant
level should be checked regularly and the radiator be blown clean.

Coolant
Coolant with anti-freeze and corrosion protection
Change coolant every 3000 hours.
When delivered from the factory, the cooling system is normally
filled with tap water mixed with Volvo concentrated anti-freeze.
This coolant mixture lowers the freezing point down to –25 °C (–
13 °F). If there is a risk that the ambient temperature will drop be-
low this temperature, the freezing point of the coolant should be
lowered further, see below.
To protect the engine from corrosion and the radiator from clogging
Anti-freeze

Kühlflüssigkeit
up, the concentrated anti-freeze contains active anti-corrosion ad-
Agent antigel
ditives. If these additives are to have any effect, at least 40 % of
Refrigerante the coolant must be concentrated anti-freeze.
eddame nto
Liquido di raffr
Recommended coolant, see page 168.

NOTE: Do not mix different makes of anti-freeze or additives

L68267A
as this can have a negative effect.

Cooling system capacity when changing:

L150E, approx. 47 litres (12.4 US gal)
L180E, approx. 70 litres (18.5 US gal)
At –25 °C (–13 °F) approx. 19 litres (5.0 US gal) of anti-freeze is
required and at –37 °C (–35 °F) approx. 23.5 litres (6.2 US gal) is
required (applies to L150E).
At –25 °C (–13 °F) approx. 28 litres (7.4 US gal) of anti-freeze is
required and at –37 °C (–35 °F) approx. 35 litres (9.2 US gal) is re-
quired (applies to L180E).
 Basic preventive maintenance
128 Cooling system

A B Coolant, checking
Check the coolant level every 50 hours.
The level should stand between the Max. and Min. marks on the
expansion tank.

Coolant, changing
Change coolant every 3000 hours.

WARNING!
L67727A
A Cap on expansion tank There is a risk of scalding when the expansion tank cap or
B Coolant Level radiator cap are removed because of the excess pressure
in a hot cooling system.

Draining, L150E
1 Remove the expansion tank cap.
2 Loosen the cover at the inside of the rear, right wheel and
swing the cover to one side.
3 Place one end of the hose (the hose lies in the battery box) in
a suitable vessel and screw the other end onto the draining
nipple.
4 Then drain the cylinder block by connecting the hose to the
draining nipple on the cylinder block.
5 The engine oil cooler should also be drained.
L67012A
Take care of waste oil and liquids in an environmentally safe
Draining point (behind right rear wheel) way!

L68999A
Draining point (on cylinder block)

L68998B

Draining point (at bottom of engine oil cooler)

 Basic preventive maintenance
Cooling system 129

Draining point, L180E

1 Remove the expansion tank cap.
2 Loosen the cover at the inside of the rear, right wheel and
swing the cover to one side.
3 Place one end of the hose (the hose lies in the battery box) in
a suitable vessel and screw the other end onto the draining
nipple.
4 Then drain the cylinder block by connecting the hose to the
draining nipple on the cylinder block.

Take care of waste oil and liquids in an environmentally safe

way!
L67012A

Draining point (behind right rear wheel)

L69000A
Draining point (on cylinder block)
Filling
Filling with coolant is done through the expansion tank.
1 The engine should not be running and the temperature control
set to warm.
2 Fill with coolant to the maximum mark on the expansion tank.
3 Run the engine until it is warm and top up the coolant level until
all air has been removed from the system.
4 The level should be checked after the engine has been run
warm and then allowed to cool.
NOTE: The system can also be filled through the draining nip-
ple.

IMPORTANT! Never fill a hot engine with cold coolant, as this

may cause the cylinder block or the cylinder head to crack.
Failure to change coolant will cause clogging of the cooling
system and the risk of engine damage.
 Basic preventive maintenance
130 Cooling system

Coolant filter
The filter should be replaced every 1000 hours.
The filter cannot be cleaned, but should be replaced with a com-
pletely new unit.

L68998C
Coolant filter, L150E

Radiator, cleaning
The radiator should be cleaned at regular intervals in order to safe-
guard the cooling of the engine. When operating under especially
dusty conditions, the radiator should be checked daily.

WARNING!
The engine must not be running when cleaning the radiator
L69014A
as the rotating parts may cause injuries.
Coolant filter, L180E

1 Open the radiator casing and swing it outward until it is fully

open.
2 Blow the radiator clean with compressed air from the outside.

NOTE: The radiator core can be easily damaged if not handled

carefully.

Coolant pump, checking

L69017A

Draining hole on coolant pump, L150E

Check every 2000 hours that the draining hole on the coolant
pump is not blocked. Clean the hole with a thin screwdriver or sim-
ilar when required.
If oil or water is leaking from the hole, this indicates a leak inside
the coolant pump.
NOTE: When operating under especially dusty conditions, the
check should be made more often.

L69014B

Draining hole on coolant pump, L180E

 Basic preventive maintenance
Electrical system 131

Electrical system
Check the travelling lights and control lamps daily.

Battery disconnect switch

If the machine is to be left unattended for some time, the battery
disconnect switch should be turned off.

Batteries
The batteries are two 12 V batteries which are connected in series
providing a system voltage of 24 V.
L67709B
Battery disconnect switch Check the electrolyte level every 250 hours (more often at
temperatures above +15 °C = +59 °F).
3 The level should be approx. 10 mm (0.4 in) above the cell
plates.
3 Top up with distilled water when required.
3 Check that the cable terminals and pole studs are clean, well
tightened and coated with petroleum jelly or similar.

The state of charge of the batteries is checked with a hydrometer.

When there is a risk of frost, it is very important that the batteries
do not become discharged as the electrolyte in a discharged bat-
tery is more likely to freeze and so destroy the battery.

Batteries, rules
L67017B

Battery box, L150E 3 Never smoke near batteries, as these give off explosive gases.
3 Do not connect a discharged battery in series with a fully
charged battery. The current surge can cause the batteries to
explode.
3 Make sure that metal objects (such as tools, rings, watch straps
etc.) do not come into contact with the battery pole studs. Pro-
: installed over the battery pole studs, as oth-
tections should be
erwise there is a risk of injuries and fire.
3 Never tilt a battery in any direction. Battery electrolyte may leak
out.
3 When removing a battery, disconnect the ground cable first.
3 When installing a battery, connect the ground cable last. The
risk of sparks, which can cause fire, is reduced.
3 When charging batteries, follow the instructions on page 132.
3 When using a spare battery to aid starting, follow the instruc-
tions on page 132.

Batteries contain substances dangerous to health and the en-

vironment. They must therefore be disposed of according to
L67726A
local and/or national regulations.
Battery box, L180E
Remember that battery electrolyte is corrosive.
 Basic preventive maintenance
132 Electrical system

Batteries, charging

WARNING!
When a battery is being charged an explosive mixture of
oxygen and hydrogen is formed. A short circuit, an open
flame or a spark in the neighbourhood of the battery can
cause a powerful explosion. Always turn off the charging
current before disconnecting the charging clips. Ventilate
well, especially if the battery is charged in a confined
L64558A space.

The battery electrolyte contains corrosive sulphuric acid. Any

electrolyte that is spilled on the skin should be removed im-
mediately. Wash with soap and plenty of water. If you get
splashes of electrolyte in your eyes or on any other sensitive
part of your body, at once rinse with plenty of water and seek
medical advice immediately.

Starting with booster batteries

WARNING!
Due to current surge, batteries can explode causing injury,
if a fully charged battery is connected to a completely dis-
charged one.

Proceed as follows:
1 Move the gear selector to neutral.
2 Apply the parking brake.
3 Check that the booster batteries or any other power source
has the same voltage as the standard batteries.
4 Never disconnect the cables from the standard batteries!
5 Connect (+) on the booster battery to (+) on the battery nearest
to the starter motor.
6 Connect the other jump lead from the (–) terminal on the boost-
er battery to the frame of the machine, for example the frame
member close to the starter motor.
7 Start the engine with the ignition key in the cab.
8 When the engine has started, first disconnect the jump lead
between the machine frame and the negative (–) terminal of
the booster battery. Then remove the jump lead between the
positive (+) terminals.
9 Re-install the insulating caps on the battery terminals.
 Basic preventive maintenance
Electrical system 133

A Alternator
B
Check the fan belt tension every 500 hours.

WARNING!
The engine must be stationary when checking the belt ten-
sion – rotating parts can cause injuries.

On machines with air conditioning the alternator and com-

pressor have one belt in common. The belt is of the Multi V
L69003A type.

Belt tension, L150E

A Attaching bolt
Belt tension, checking
B Adjusting screw
1 At correct belt tension it should be possible to deflect the belt
approx. 8 mm (0.31 in) applying a force of 25–30 N (approx.
2.5–3.0 kgf = 5.6–6.7 lbf).

Belt tension, adjusting, L150E

1 Slacken the alternator attaching bolt (A).
2 Adjust to the correct belt tension using adjusting screw (B),
A B check the belt tension and tighten down the attaching bolt.

Belt tension, adjusting, L180E

1 Slacken the alternator attaching bolts (B)
2 Adjust to the correct belt tension using adjusting screw (A),
check the belt tension and tighten down the bolts.

The alternator installation is sensitive to faulty connection,

therefore always follow the instructions below:

L69005A Disconnecting battery

Belt tension, L180E 3 Turn off the battery disconnect switch.
A Adjusting screw 3 Battery and alternator cables must not be disconnected while
B Attaching bolt the engine is running. This can damage the alternator.
3 Disconnect and insulate the battery cables before carrying out
any work on the alternator equipment.
 Basic preventive maintenance
134 Electrical system

Battery connection
3 Turn off the battery disconnect switch.
3 The battery terminals must never be confused. Each terminal is
clearly marked with a (+) or a (–) sign respectively. If the cables
are wrongly connected, the alternator rectifier is destroyed im-
mediately.

Electric welding
3 Before electric welding is carried out on the machine or attach-
ment, turn off the battery disconnect switch.
3 Because of electrical system sensitivity the ECUs must be dis-
connected before welding. Contact authorised dealer work-
shop.
3 Connect the welding equipment ground lead as close to the
welding point as possible.
See also page 112.

Air filter, alternator (optional equipment)

Replace the filter every 2000 hours.

1000754

Air filter, alternator L150E

Relays and fuses

Relays and fuses are positioned in the electrical distribution box
1000755 behind the operator seat and become accessible after the cover
Air filter, alternator L180E
for the electrical distribution box has been opened. A decal on the
inside of the cover shows which current consuming device that is
connected to the respective relay and fuse. See also pages 172
and 187.
Never install a fuse with a higher rating than that given on the
decal (there is a risk of damage or fire on the circuit board).
If a fault should arise in one of the relays, this can be temporarily
remedied by replacing the faulty relay with another relay which has
a less important function.
 Basic preventive maintenance
Electrical system 135

Headlamps, adjusting
The headlight adjustment is of great importance in order to avoid
dazzling on-coming traffic. The headlights are of the asymmetrical
type, which means that one has to take extra care when adjusting.
Place the machine, which must not be loaded, on level ground at
right angles to a wall or similar.
Adjust the upper boundary (H) of the low beams at a distance of
(L) from the headlamps. Check the distance (Y) between the cen-
tres of the high beams. The distance should be the same as be-
tween the headlamps on the machine.

H X

L R
L69004A

Adjusting measurements
L = 5000 mm (16 ft 4.8 in)
H = (1430+R) multiplied by 0.875
((4 ft 8.3 in + R) multiplied by 0.875)
Y = 2100 mm ((6 ft 10.7 in)
X = 1430 mm (4 ft 8.3 in)
R = The distance from the floor / the ground to the centre of the front wheel hub
 Basic preventive maintenance
136 Transmission

Transmission
Transmission oil level, checking
Check the oil level every 500 hours.
When checking, the machine should stand on level ground, with
the gear selector in neutral position and applied parking brake.
When checking the oil with the engine running and the machine at
working temperature, the level should stand between the markings
High and Low in the lower part of the glass.
It is also possible to estimate the level before starting the engine
(cold oil). The level should then stand between the markings High
and Low in the upper part of the glass.

L68330A
Transmission, changing oil
Level sight glass, transmission oil
Change oil every 2000 hours.

WARNING!
Take care when changing oil, as hot oil can cause burns to
unprotected skin.

Draining
The oil is drained at the drain plug on the machine when it is at
working temperature.

Filling
Fill with oil through the filler pipe.
1 Fill with oil until the level stands between the markings High
L63529A
and Low in the upper part of the glass.
2 If the machine is at working temperature, the oil level should
stand between the markings High and Low in the lower part of
Draining, transmission oil
the glass.
3 Top up with oil if the level stands below the Low mark when the
machine is at working temperature.

Oil capacity when changing: approx. 45 litres (11.9 US gal)

For oil quality grades, see page 167.

Take care of waste oil and liquids in an environmentally safe

way!

L67016A

Filler pipe, transmission oil

 Basic preventive maintenance
Transmission 137

Suction strainer
Clean the strainer every 2000 hours in connection with chang-
ing the oil.
1 Remove the cover and clean the suction strainer.
2 Replace gaskets when required.
3 Fill oil.
4 Check that there are no leaks.

L63530A

Cover, suction strainer

Transmission, replacing oil filter

Replace the filter every 2000 hours or if the amber central
warning lamp flashes at the same time as alarm text is shown
on the display unit.
The oil filter is of the "spin on" type filter and cannot be cleaned,
but must be replaced.

L67705A

Oil filter, transmission

Transmission, breather filter

Replace the filter every 2000 hours.
The filter cannot be cleaned, but must be replaced.
L68328C

Breather filter, transmission, L150E

 Basic preventive maintenance
138 Front and rear axles

Front and rear axles

Axles, changing oil
Change oil every 1000 hours.If the machine is equipped with
axle oil cooling, the oil should be changed every 2000 hours.
Operate the machine for a few minutes and check the oil level
again. Topping up may be required.

Front axle
A Level check and filling
B Draining WARNING!
Take care when changing oil, as hot oil can cause burns to
unprotected skin.

Draining
– Drain the oil from axle (B) and hub (C) respectively.
B

Take care of waste oil and liquids in an environmentally safe

way!
L67011A

Rear axle
A Level check and filling
B Draining point

Axles, capacities
Oil capacity front axle when changing, 45 litres (11.9 US gal)
(incl. differential carrier assembly and hubs).
Oil capacity rear axle when changing, 55 litres (14.5 US gal)
(incl. differential carrier assembly and hubs).

For oil quality grades, see page 167.

C
NOTE: After having changed a tyre or if the wheel has been
removed and installed for any other reason, the wheel bolts
must be check-tightened after eight hours of operation. The
L63534B
tightening torque is 600 ±50 N m (443 ±37 psi).
Front and rear axles
C Draining point, hub
 Basic preventive maintenance
Front and rear axles 139

Axles, oil cooling (optional equipment)

Replace filters every 2000 hours.
The filters cannot be cleaned, but must be replaced.

L69016A

L67866A
L67867A

Axle oil cooling, front axle Axle oil cooling, rear axle, L150E Axle oil cooling, rear axle, L180E

Breather filters, axles

Replace filters every 2000 hours.
The filter cannot be cleaned, but must be replaced.

L68329B
L64147A

L69015A
Breather filter, front axle Breather filter, rear axle, L150E Breather filter, rear axle, L180E

Lubrication of propeller shafts

Lubricate the shafts every 500 hours, see page 150.
In aggressive/corrosive environment lubrication should be carried
out every 50 hours.
 Basic preventive maintenance
140 Brake system

Brake system
The brake system is all hydraulic and uses the same oil tank as the
working hydraulics and the steering system.
For checking and changing oil, see page 147.

Before opening the system or check-tightening leaking couplings

and connections, the pressure in the brake system must be re-
leased. This is done by stopping the engine and depressing the
brake pedal several times (30–40 times).

WARNING!
Even if the engine has been stopped, there is still an accu-
mulated pressure in the system. If the system is opened,
without having first released the pressure, oil under high
pressure will jet out and this could cause injuries.

3 Discarded accumulators should be taken care of by a workshop

and "punctured".
3 There is a risk of explosion if an accumulator is heated.

Brake discs, checking

The brake disc wear should be checked every 1000 hours and
L62829D when changing tyres.
Cap nut on wear indicator – Start the engine to charge the brake system.
– Stop the engine and apply the brake.
NOTE: The brake must be applied during the entire wear
check.
– Remove the cap nut on the wear indicator and press in the pin
against stop. The position of the flat face on the pin indicates
how much the brake disc is worn. If the face is level with the flat
face on the nipple, the brake disc is worn out and must be re-
placed by an authorised dealer workshop.
– Install the cap nut on the wear indicator and carry out the same
check of the other brake discs.

Brakes, air bleeding

If bleeding the brake system is necessary, this should be done by
L62829C
an authorised dealer workshop.
Brake discs, checking
 Basic preventive maintenance
Brake system 141

Parking brake, checking

WARNING!
Brake test and checking the parking brake should only be
done within an area where it cannot cause accidents.

1 Apply the parking brake.

2 With 3rd gear engaged and engine at full speed, the machine
should remain stationary.

Brake test, see page 77.

 Basic preventive maintenance
142 Cab

Cab
Cab, ventilation filters
The cab ventilation filters consist of prefilter and main filter. The
clogging up of the filters is entirely dependent on the working en-
vironment of the machine, but the filters should be checked once
A a week.
The main filter should be replaced every 2000 hours and the
prefilter every 1000 hours.
B NOTE: The interval between filter replacements can be in-
creased or reduced depending on how dusty the working en-
L66600B
vironment is.
A Prefilter NOTE: The cab filters are only intended to separate particles
(dust) from the air. Any dangerous gases are not trapped by
B Primary filter
the filters.

Cleaning
1 Use a respirator (face mask).
2 Open the side cover and remove the filters.
3 Carefully shake the filters without damaging them. Avoid using
compressed air, vacuum cleaner or water.

Asbestos filter
The filter is especially intended for use in environments where
there may be asbestos dust, but it is of course effective against all
other kinds of dust when the operator needs highly filtered air in
the cab.
Testing: The filter meets the requirements according to DOPMIL
standard 282 and thereby also the requirements of the National
Swedish Board of Occupational Safety and Health regulations As-
bestos AFS 1992:2.
It also meets the requirements according to DIN 24184 filter class
S. Observe the national regulations for the environment you are
actually working in.
 Basic preventive maintenance
Cab 143

Asbestos
Advice for operating in environments where dust / asbestos
dust is present
3 It is important that the cab is kept free from dust / asbestos dust
as far as possible:
– Enter and leave the machine in a place away from the as-
bestos contaminated area.
– Keep clothes and shoes clean from dust.
– Tidy and vacuum-clean the cab often and use personal
protective equipment, for instance respirator (dust mask)
intended for asbestos contaminated areas.
– Make sure that the cab door is kept closed while operat-
ing.
3 The cab should be ventilated through its ventilation system,
which also provides excess pressure in the cab.
3 Replace filters (main filter and prefilter) every 1000 hours or
more often when necessary and be careful with the new filter
so that it is not damaged.
3 With regard to risks to health and environment, used filters
must be placed in the sealable plastic bag which is supplied to-
gether with new filters. The bag with the used filter should then
be deposited at a place authorised to take care of asbestos
waste.
 Basic preventive maintenance
144 Operator seat, lubrication

Operator seat, lubrication

If sqeaking noises arise, the seat should be lubricated as shown
below:
1 Remove bolts (A).
2 Fold up seat (B).
3 Lubricate linkage (C) on both sides with oil.
4 Lubricate spring ends (D) with grease.

5 Remove the four plastic plugs retaining the rubber bellows and
push down the bellows. Lubricate linkages (E) on both sides
with oil.
6 Lubricate slide rails (F) on both sides with grease.
 Basic preventive maintenance
Air conditioning (optional equipment) 145

Air conditioning (optional equipment)

Ask personnel at an authorised dealer workshop to check the
air conditioning once a year.
Refrigerant (R134a)
The pressurised system contains HFC – refrigerant R134a. It
is illegal to purposely release refrigerant into the open air.
Any service, refilling or emptying of the refrigerant circuit
must only be carried out by a trained and accredited person.

The air-conditioning unit of the machine is filled with refrigerant

R134a at the factory. This refrigerant has been developed as an al-
ternative to the earlier refrigerant R12 (Freon), as the R134a has
less environmental impact.
R134a has, in difference to R12, no potentially depleting properties
that will affect the ozone layer of the atmosphere, but as R134a is
a so called greenhouse gas, it must never intentionally be released
into the open air.
NOTE: R134a must never be mixed with R12, as this would
cause the air-conditioning unit to fail.

WARNING!
Refrigerant R134a easily causes frost-bite, if it comes into
contact with bare skin. When heated gases are formed,
which can be harmful to the lungs and nervous system
even at low concentrations, when no smell is apparent. The
symptoms may arise several hours (even up to 24 hours)
after exposure to the gas.

Suspected leakage
The system is pressurised and the refrigerant can unintentionally
leak out. Never disconnect hoses and never remove the filler plug
from the compressor.
If a leak is suspected, the system must not be topped up –
leave the area where the leak has taken place and contact per-
sonnel at an authorised dealer workshop for action to be tak-
en.

First aid measures

In case of accidental contact with escaping refrigerant, take
the following measures:
– Refrigerant in gas form and when heated can, in low concen-
trations, have an effect, particularly on the nervous system. At
high concentrations, the gas has a narcotic effect. In both cas-
es move personnel from the danger area out into the fresh air.
If someone is seriously affected, seek medical advice.
– If large amounts of liquid refrigerant has come into contact with
unprotected skin, the injured area should be carefully warmed
with lukewarm water or warm clothes. Seek medical advice if
there are remaining symptoms.
– If liquid refrigerant has come into contact with someone's eyes,
seek medical advice.
 Basic preventive maintenance
146 Air conditioning (optional equipment)

Compressor
On machines equipped with air conditioning the alternator and
compressor have one belt in common. The belt is of the Multi V
type.
Check the belt tension every 500 hours, see page 133.

WARNING!
The engine must be stationary when checking the belt ten-
sion – rotating belts can cause injuries.

In order to prevent leakage and to safeguard the lubrication of the

seals in the compressor for the air conditioning, the air conditioning
should be run for at least five minutes once a month.
At temperatures below freezing, 0 °C (+32 °F), the unit must
be run indoors, as the power supply to the compressor lead
is switched off by the thermostat whenever the evaporator
temperature is below +1 °C (+34 °F).
NOTE: Make sure that the exhaust gases are extracted or re-
moved by ventilation in a suitable way.

Condenser
Cleaning
Clean the condenser at regular intervals as follows:
1 Swing out the radiator casing.
2 Blow the condenser clean with compressed air.

If the pressure in the system becomes too high because of a

clogged condenser, the air conditioning will cut out. The con-
denser must first be cleaned before the system is restarted
with the switch.
L67722B
Condenser

Evaporator
Cleaning
NOTE: High-pressure wash must not be used!
Clean the evaporator at regular intervals. Use a soft brush, not
compressed air.
For a more thorough cleaning, the evaporator must be loosened
from its mountings and cleaned from the rear. Therefore this ought
to be done at an authorised dealer workshop.

L65987D

Evaporator
 Basic preventive maintenance
Hydraulic system 147

Hydraulic system
The same hydraulic oil tank is used for working hydraulics, brake
and steering systems.
Any work on the system requires great demands on cleanli-
ness. Even very small particles can cause damage or clog up
the system. Therefore, wipe areas in question clean before
any work is carried out.
The pressure-limiting valves for the hydraulic system are set to the
correct value at the factory. If the valves are altered by any person
other than service personnel at an authorised dealer workshop,
L67724B the guarantee from the manufacturer will be void.
Oil level, hydraulic oil

Hydraulic system, checking oil level

Check the oil level every 250 hours. The level should stand
between the Max. and Min. marks on the level sight glass (po-
sitioned on the left side of the machine).
NOTE: The oil level should be checked when the lifting arms
are in their lowest position and with the attachment flat on the
ground.
Filling is done from the top of the hydraulic tank, see page 147.

Hydraulic system, changing oil

(working hydraulics, brake and steering systems)
Change every 4000 hours if the system is filled with hydraulic
oil.
Change oil every 2000 hours, if the system is filled with en-
gine oil or biologically degradable hydraulic oil.
NOTE: When using attached external hydraulic equipment,
e.g. road sweeper, drill, snow blower or similar, the oil should
be changed at shorter intervals, i.e. every 1000 hours.
Oil capacity of the hydraulic tank when changing: 156 litres
(41.2 US gal)

For oil quality grades, see page 167.

WARNING!
Take care when changing oil, as hot oil can cause burns to
unprotected skin.
 Basic preventive maintenance
148 Hydraulic system

Draining
NOTE: Use the same hose as for draining the engine oil, (po-
sitioned in the battery box). Temporarily replace the rubber
hose with a 3/4 inch inside diameter hose which is at least 3.5
m (12 ft) long in order to reach the collecting vessel.
1 Operate the machine until the oil reaches normal working tem-
perature.
2 Stand the machine on level ground with the bucket (attach-
ment) lowered to the ground.
3 Stop the engine and release the pressure in the brake system
L67767A
by depressing the brake pedal several times.
4 Unscrew the protective cover from the draining point.
5 Place one end of the hose in a vessel for collecting the oil and
screw the other end of the hose into the draining point.
6 Then proceed to drain from the other side.
Draining points for hydraulic oil
Hydraulic system, draining sludge
Drain sludge and condensation water from the hydraulic oil tank
via the draining point on the right side every 1000 hours.

Take care of waste oil and liquids in an environmentally safe

way!

Filling
1 Fill with oil to correct level.
D 2 Start the engine and operate the lifting and tilting cylinders to
both end positions.
3 Top up with oil when required.
4 Check that there are no leaks.

Hydraulic system, return oil filter

Replace return oil filter every 2000 hours.
1 Remove the cover.
A B C 2 Lift out and take apart the filter insert.
3 Remove the filter which is of the disposable type and install a
new filter. Check the seal rings when installing.
L67840A

A Breather filter
B Cover, return oil filter Hydraulic system, breather filter
C Cover, filling point
D Cover, oil strainer
The filter should be replaced every 2000 hours.
The filter cannot be cleaned, but must be replaced.
 Basic preventive maintenance
Tyres 149

Tyres
Inflating tyres
Recommended tyre pressures should normally be followed. Spe-
cial operations may justify a different pressure. In such cases, fol-
low the instructions from the tyre manufacturer and do not exceed
the maximum permissible pressures, see pages 178 and 193.
The tyre pressure may have been raised before the machine was
delivered from the factory. Therefore, check and adjust the tyre
pressure according to recommendations, before putting the ma-
chine to work for the first time.

WARNING!
Repair work on tyres and rims must be carried out by per-
sons who have been especially trained for this.

The instructions stated below apply to an inflated tyre where

the pressure needs to be increased. If the tyre has lost all
pressure, a trained service engineer should be called in.
– When checking the air pressure, the tyre should be cold and
the machine be without a load.
– Ask all other persons to leave the danger area (in front of the
rim).
– Stand by the tyre tread as shown in the figure. Tyre installed on
a split rim may explode causing injury or in the worst case
death.
– Use a long air hose (with a self-attaching air chuck) which al-
lows you to stand outside the danger area.
– Tyres on stored wheels (spare wheels) should be kept in a lying
down position and only be inflated sufficiently to keep the rim
parts in position.

Wheel bolts, check-tightening

After having changed a tyre or if the wheel has been removed and
installed for any other reason, the wheel bolts must be check-tight-
ened after eight hours of operation.
 Basic preventive maintenance
150 Greasing bearings

Greasing bearings
The service life of bushings and pivot pins can be extended con-
siderably, if the machine is greased regularly and in the correct
way.
Wipe off grease nipples and grease gun before greasing, so
that dirt and sand is not introduced through the grease nip-
ples.
The greasing of bearings has two main purposes:
– Add grease to the bearing to reduce friction between pin and
bushing.
– Replace old grease which may contain dirt. The grease in the
L63189A space inside the outer seal collects dirt and prevents dirt and
also water from penetrating into the bearing.
Therefore, grease the bearing until new, clean grease is forced out
through the outer seal.

Symbol key
These standard symbols are used in the "Lubrication and Service
Chart" on pages 152 and 154.

Engine
L66544A

Lubrication

Transmission Oil/liquid
L66542A

L66627A

L66625A

Hydraulic system Filter

L66543A

L 6 66 37 A
Brake system Air filter
L66626A

Axles Level check

L 66636A

Fuel system L 666 39 A

Belt tension
L66546A

Battery Control lamps

L66633A

L66638A

Coolant L66632A
Draining
L66629A

Air conditioning
L66640A
 Basic preventive maintenance
Service schedule 151

Service schedule
The schedule shows which measures should be taken at the respective hour meter readings. Example: When the
machine has been operated for 1500 hours the Daily, 50, 250 and 500 hour services should be carried out ac-
cording to the "Lubrication and Service Chart", see pages 152 and 156 respectively. After completed service,
make a tick in the appropriate box.
Service intervals
Daily service (should always be carried out first)
A 50 hours
B 250 hours
C 500 hours
D 1000 hours
E 2000 hours

50 A 2050 A 4050 A 6050 A 8050 A

100 A 2100 A 4100 A 6100 A 8100 A
150 A 2150 A 4150 A 6150 A 8150 A
200 A 2200 A 4200 A 6200 A 8200 A
250 AB 2250 AB 4250 AB 6250 AB 8250 AB
300 A 2300 A 4300 A 6300 A 8300 A
350 A 2350 A 4350 A 6350 A 8350 A
400 A 2400 A 4400 A 6400 A 8400 A
450 A 2450 A 4450 A 6450 A 8450 A
500 ABC 2500 ABC 4500 ABC 6500 ABC 8500 ABC

550 A 2550 A 4550 A 6550 A 8550 A

600 A 2600 A 4600 A 6600 A 8600 A
650 A 2650 A 4650 A 6650 A 8650 A
700 A 2700 A 4700 A 6700 A 8700 A
750 AB 2750 AB 4750 AB 6750 AB 8750 AB
800 A 2800 A 4800 A 6800 A 8800 A
850 A 2850 A 4850 A 6850 A 8850 A
900 A 2900 A 4900 A 6900 A 8900 A
950 A 2950 A 4950 A 6950 A 8950 A
1000 ABCD 3000 ABCD 5000 ABCD 7000 ABCD 9000 ABCD

1050 A 3050 A 5050 A 7050 A 9050 A

1100 A 3100 A 5100 A 7100 A 9100 A
1150 A 3150 A 5150 A 7150 A 9150 A
1200 A 3200 A 5200 A 7200 A 9200 A
1250 AB 3250 AB 5250 AB 7250 AB 9250 AB
1300 A 3300 A 5300 A 7300 A 9300 A
1350 A 3350 A 5350 A 7350 A 9350 A
1400 A 3400 A 5400 A 7400 A 9400 A
1450 A 3450 A 5450 A 7450 A 9450 A
1500 ABC 3500 ABC 5500 ABC 7500 ABC 9500 ABC

1550 A 3550 A 5550 A 7550 A 9550 A

1600 A 3600 A 5600 A 7600 A 9600 A
1650 A 3650 A 5650 A 7650 A 9650 A
1700 A 3700 A 5700 A 7700 A 9700 A
1750 AB 3750 AB 5750 AB 7750 AB 9750 AB
1800 A 3800 A 5800 A 7800 A 9800 A
1850 A 3850 A 5850 A 7850 A 9850 A
1900 A 3900 A 5900 A 7900 A 9900 A
1950 A 3950 A 5950 A 7950 A 9950 A
2000 ABCDE 4000 ABCDE 6000 ABCDE 8000 ABCDE 10000 ABCDE

L62291B
 Basic preventive maintenance
152 Lubrication and service chart, L150E

Lubrication and service chart, L150E

Checks, oil changes and lubrication
Intervals:
Daily, 50, 250, 500, 1000 and 2000 hours (for symbol key, see page 150)

25 20 17 17 1
24 2000 h
26 1000 h 26
500 h
250 h
27 50 h
10 h
2
6

12 4
9

7
5
2 23

13 15

15
22

2 21
8

19 2 3

10 6
3
16
4
1
-+ 7

2
8 1 6
10 h
50 h
250 h
500 h
14 1000 h 14
F R
2000 h
L150E 12 11 18 8 12
L68940A
 Basic preventive maintenance
Lubrication and service chart, L150E 153

Ite Page Measure

m
DAILY (every 10 hours)
1 Check function of control lamps
126 Check oil-bath precleaner oil level (optional equipment)
Check travel lights, working lights, reversing alarm

A = EVERY 50 HOURS
After carrying out Daily service
2 118 Check engine oil level
3 128 Check coolant level
178 Check tyres (air pressure and damage) 1)

4 150 Lubricate lifting frame 2)

B = EVERY 250 HOURS

After carrying out Daily and A services
5 147 Check hydraulic system oil level
6 123 Check fuel system water trap
7 131 Check battery electrolyte level
Check for any leaks
8 150 Lubricate steering cylinder bearings, rear axle pivot bearing and frame
joint upper bearing 3)

C = EVERY 500 HOURS

After carrying out Daily, A and B services
2 118, 119 Change engine oil and replace oil filter 4)

9 133 Check belt tensions incl. compressor belt

10 136 Check transmission oil level
5)
11 139 Lubricate propeller shafts and support bearing

1) If the machine is used for handling sharp rocks, a check should be carried out daily.
2) During difficult operating conditions these should be lubricated daily.
3) In aggressive/corrosive environment lubrication should be carried out every 50 hours.
4) For conditions which have to be met, if the interval is to apply, see page 118.
5) In aggressive/corrosive environment lubrication of the universal joints should be carried out every 50 hours.
Splined joints should only be lubricated when necessary.
 Basic preventive maintenance
154 Lubrication and service chart, L150E

Checks, oil changes and lubrication

Intervals:
Daily, 50, 250, 500, 1000 and 2000 hours. (For symbol key, see page 150)

25 20 17 17 1
24 2000 h
26 1000 h 26
500 h
250 h
27 50 h
10 h
2
6

12 4
9

7
5
2 23

13 15

15
22

2 21
8

19 2 3

10 6
3
16
4
1
-+ 7

2
8 1 6
10 h
50 h
250 h
500 h
14
F
1000 h 14
R
2000 h
L150E 12 11 18 8 12
L68940A
 Basic preventive maintenance
Lubrication and service chart, L150E 155

Ite Page Measure

m
D = EVERY 1000 HOURS
After carrying out Daily, A, B and C services
12 138 Change oil in front and rear axles 6)
13 148 Drain sludge and condensation water from the hydraulic system
14 140 Check brake discs
15 125 Replace air cleaner primary filter
6 120 Replace fuel filters
16 130 Replace coolant filter
17 142 Replace cab ventilation filter (prefilter) 7)
18 150 Lubricate frame joint lower bearing
19 150 Lubricate cab door hinges8)
20 150 Lubricate side window hinges 8)

E = EVERY 2000 HOURS

After carrying out Daily, A, B, C and D services
10 136 Change transmission oil and clean suction strainer
21 137 Replace transmission breather filter
22 137 Replace transmission oil filter
23 147 Change hydraulic system oil9)
24 148 Replace hydraulic system return oil filter
25 148 Replace hydraulic system breather filter
17 142 Replace cab ventilation filter (main filter) 7)

15 125 Replace air cleaner secondary filter

26 139 Replace axle breather filters
27 123 Replace the fuel system breather filter
134 Replace alternator air filter (optional equipment)
130 Check coolant pump draining hole
Work that should be carried out by authorised dealer workshop
Check turbocharger including inlet and exhaust systems
Check valve clearance, engine
Check engine speed, high and low idling

EVERY 3000 HOURS

After carrying out Daily, A, B, C, D and E services
3 128 Change coolant

6) If the machine is equipped with filter for axle oil cooling, the oil should be changed every 2000 hours
7) Replace the cab filter more often when required
8) Lubricate more often when required.
9) If the system is filled with hydraulic oil, the oil should be changed every 4000 hours (if it is filled with engine
oil or biologically degradable hydraulic oil, the oil should be changed every 2000 hours).

Machines with automatic greasing, see page 161.

 Basic preventive maintenance
156 Lubrication and service chart, L180E

Lubrication and service chart, L180E

Checks, oil changes and lubrication
Intervals:
Daily, 50, 250, 500, 1000 and 2000 hours (for symbol key, see page 150)

15 24 25 20 17 17 1
15 2000 h
26 1000 h 26
500 h
250 h
27 50 h
10 h
2
6

12 4
9

7
5
2 23

13

22 2 21

2 3
8

19 3
16
10
1
-+ 7

4 2
8 1 6
10 h
50 h
250 h
500 h
14
F
1000 h 14
R
2000 h
L180E 12 11 18 8 12
L68940B
 Basic preventive maintenance
Lubrication and service chart, L180E 157

Ite Page Measure

m
DAILY (every 10 hours)
1 Check function of control lamps
126 Check oil-bath precleaner oil level (optional equipment)
Check travel lights, working lights, reversing alarm

A = EVERY 50 HOURS
After carrying out Daily service
2 118 Check engine oil level
3 128 Check coolant level
193 Check tyres (air pressure and damage) 1)

4 150 Lubricate lifting frame 2)

B = EVERY 250 HOURS

After carrying out Daily and A services
5 147 Check hydraulic system oil level
6 123 Check fuel system water trap
7 131 Check battery electrolyte level
Check for any leaks
8 150 Lubricate steering cylinder bearings, rear axle pivot bearing and frame
joint upper bearing 3)

C = EVERY 500 HOURS

After carrying out Daily, A and B services
2 118, 119 Change engine oil and replace oil filter 4)

9 133 Check belt tensions incl. compressor belt

10 136 Check transmission oil level
5)
11 139 Lubricate propeller shafts and support bearing

1) If the machine is used for handling sharp rocks, a check should be carried out daily.
2) During difficult operating conditions these should be lubricated daily.
3) In aggressive/corrosive environment lubrication should be carried out every 50 hours.
4) For conditions which have to be met, if the interval is to apply, see page 118.
5) In aggressive/corrosive environment lubrication of the universal joints should be carried out every 50 hours.
Splined joints should only be lubricated when necessary.
 Basic preventive maintenance
158 Lubrication and service chart, L180E

Checks, oil changes and lubrication

Intervals:
Daily, 50, 250, 500, 1000 and 2000 hours. (For symbol key, see page150)

15 24 25 20 17 17 1
15 2000 h
26 1000 h 26
500 h
250 h
27 50 h
10 h
2
6

12 4
9

7
5
2 23

13

22 2 21

2 3
8

19
3
16
10
1
-+ 7

4 2
8 1 6
10 h
50 h
250 h
500 h
14 1000 h 14
F R
2000 h
L180E 12 11 18 8 12
L68940B
 Basic preventive maintenance
Lubrication and service chart, L180E 159

Ite Page Measure

m
D = EVERY 1000 HOURS
After carrying out Daily, A, B and C services
12 138 Change oil in front and rear axles 6)
13 148 Drain sludge and condensation water from the hydraulic system
14 140 Check brake discs
15 125 Replace air cleaner primary filter
6 120 Replace fuel filters
16 130 Replace coolant filter
17 142 Replace cab ventilation filter (prefilter) 7)
18 150 Lubricate frame joint lower bearing
19 150 Lubricate cab door hinges8)
20 150 Lubricate side window hinges 8)

E = EVERY 2000 HOURS

After carrying out Daily, A, B, C and D services
10 136 Change transmission oil and clean suction strainer
21 137 Replace transmission breather filter
22 137 Replace transmission oil filter
23 147 Change hydraulic system oil9)
24 148 Replace hydraulic system return oil filter
25 148 Replace hydraulic system breather filter
7)
17 142 Replace cab ventilation filter (main filter)
15 125 Replace air cleaner secondary filter
26 139 Replace axle breather filters
27 123 Replace the fuel system breather filter
134 Replace alternator air filter (optional equipment)
130 Check coolant pump draining hole
Work that should be carried out by authorised dealer workshop
Check turbocharger including inlet and exhaust systems
Check valve clearance, engine
Check engine speed, high and low idling

EVERY 3000 HOURS

After carrying out Daily, A, B, C, D and E services
3 128 Change coolant

6) If the machine is equipped with filter for axle oil cooling, the oil should be changed every 2000 hours
7) Replace the cab filter more often when required
8) Lubricate more often when required.
9) If the system is filled with hydraulic oil, the oil should be changed every 4000 hours (if it is filled with engine
oil or biologically degradable hydraulic oil, the oil should be changed every 2000 hours).

Machines with automatic greasing, see page 161.

 Basic preventive maintenance
160 Automatic greasing

Automatic greasing
The machine may be equipped with an automatic greasing system
which automatically lubricates several points at preselected inter-
vals. The greasing system should be inspected regularly prefera-
bly in conjunction with other periodical maintenance and checks.
Check the following regularly:
– that there is sufficient lubricant in the reservoir. Fill when
required, see page 162.
NOTE: Too low lubricant level means great risk of air
entering the system (the most common error cause).
– that the system functions. Carry out the system test on
page 164.
– that the lubricant reservoir is undamaged.
– that the connections do not leak.
– that the dust guards for quick-action couplings are in-
stalled and undamaged.
– that the lubrication lines are undamaged and well se-
cured.
– that all lubrication points are lubricated (that lubricant is
forced out at bearings and joints).
NOTE: Remember to lubricate by hand the lubrication points
which are not included in the automatic greasing system. See
the ordinary lubrication chart.

1 Pump unit with automatics

2 Battery
3 Metering block
4 Metering valve
5 V-ECU
6 Lubrication pressure sensor
7 Main line A
8 Main line B
9 Ignition switch
10 Switch
11 Control lamp
12 System testing button
13 Filling point
 Basic preventive maintenance
Automatic greasing 161

Lubrication points

1 Lifting frame 6 Frame joint bearings, upper and lower bearings

2 Hydraulic attachment bracket 7 Steering cylinder, front and rear bearings
3 Lifting cylinder, front and rear bearings 8 Bucket attachment, upper and lower attachments
4 Tilting cylinder, front and rear bearings 9 Rear axle bridge
5 Propeller shafts, front and rear support bearings
 Basic preventive maintenance
162 Automatic greasing

Filling lubricant
Lubricant must be topped up before the level falls below the
minimum marking on the reservoir.
On the pump unit there is a filler connection (grease nipple) to
which a hand pump or an industrial pump are connected when fill-
ing.
NOTE: If an industrial type pump is used, the filter between
connection and pump should be cleaned regularly. A partly
blocked filter can easily burst, with a consequent great risk of
small particles entering the lubrication system. This may in
turn lead to a breakdown in the lubrication system.

Proceed as follows:
1 Carefully clean the filler connection and the coupling on the fill-
er hose.
Filler connector 2 Fill the filler hose completely full with grease before beginning
to fill. This will prevent air from entering the system.
3 Remove the protective cap on the filler connection and con-
nect the coupling to the filler connection.
4 Fill with lubricant to the max. level on the reservoir.*) If it is hard
to pump in the lubricant, either the filter behind the filler con-
nection is blocked or there may be dirt in the filler nipple itself.
Clean the filter, if required replace the nipple and try again.
5 Re-install the protective cap.
6 Keep the lubrication pump in a dust-free place, so that it will
not be exposed to dirt.
*) If the reservoir is filled above the maximum level, the surplus lu-
bricant will be drained through the ventilation hole on the left side
of the reservoir. Any air under the plate in the reservoir is also
drained through the ventilation hole.

Recommended lubricants
Tempera- The system requires that the lubricant is clean and possible to
NLGI class grease pump at the prevailing temperature. A lower NLGI class grease,
ture may reduce the lubrication effect with increased wear as a conse-
quence.
Between –25 2
°C (–13 °F) 3 Do not mix different types of lubricant. When changing, all lubri-
and +80 °C cant must be changed, not only in the reservoir.
(+176 °F) 3 There must be no additives of graphite or teflon in the lubricant.
Below –25 °C 1 or alternatively 3 The use of molybdenum disulphide (MoS2) is only permitted if:
(–13 °F) 2 of a special type based – the lubricant is of a very high quality and does not contain
on synthetic oil. Care- more than 5 % MoS2.
fully check against the – the lubrication system is regularly checked to provide reli-
manufacturer’s specifica- able operation.
tions before using the lat-
ter alternative. – the main lines are flushed through at least once a year.
 Basic preventive maintenance
Automatic greasing 163
Control lamp
The control lamp is built into the switch on the front right instrument
panel and has the following functions:
– Shows the selected lubrication cycle
– Fault indicator

L66303A
The control lamp also functions as a test lamp during trouble-
Switch for changing lubri- shooting by service personnel.
cation cycle

The control lamp flashes: Cause

four times when the ignition key is turned from the "0" 4 x 1 flash: The lubrication cycle set to position for
position very demanding conditions.
4 x 2 flashes: Normal position
4 x 3 flashes: Light conditions
for two minutes each time an lubrication cycle is initi- Low lubricant level, fill the reservoir
ated
two seconds on, two seconds off Single test lubrication cycle in progress
0.2 seconds on, 0.2 seconds off Continuous test lubrication cycle in progress
The control lamp lights:
continuously for two minutes after completed pump- The lubrication pressure sensor is not activated. Con-
ing phase, i.e. the first part of the lubrication cycle tact personnel at an authorised dealer workshop.
continuously The control unit has interrupted the signal to the pump
and the shuttle valve. Contact personnel at an author-
ised dealer workshop.

NOTE: Special tools are required for fault tracing, adjusting

and repairing the control unit. Therefore, contact qualified
service personnel when required.

Changing lubrication cycle

If the preselected lubrication cycle does not suit the working and
loading conditions to which the machine is exposed, the operator
can alter the lubrication cycle. This is done with the switch on the
front right instrument panel.
1 Turn the ignition key to position 1 (running position).
NOTE: The control lamp should flash. If it does not do that, or
if it lights continuously, the system must be checked immedi-
ately.
2 Press the switch within 30 seconds, once, twice or three times
in quick succession, depending on which lubrication cycle is to
be selected.
– Pressing once will provide lubrication at short intervals for
very demanding conditions.
– Pressing twice will provide lubrication at normal intervals
for normal conditions.
– Pressing three times will provide lubrication at long inter-
vals for light conditions.
3 After approx. two seconds the control lamp flashes once, twice
or three times depending on which lubrication cycle that has
been selected.
NOTE: Wait for at least 20 seconds after the selection has
been completed before turning the ignition key to position 0,
otherwise the latest selected lubrication cycle will be erased.
 Basic preventive maintenance
164 Automatic greasing

System test
In order to check the function of the greasing system, or to initiate
an extra lubrication cycle after for example the machine has been
washed, a system test can be carried out. The test button, which
is used to begin a system test, is positioned at the front on the
pump.
A test cycle can only be carried out when the pump is between two
ordinary lubrication cycles (not during an ongoing lubrication cy-
cle).

Single test lubrication cycle

The pump only carries out one lubrication cycle via one main
line. May be used after a wash in order to obtain an extra
lubrication cycle.
1 Turn the ignition key to position 1 (running position).
2 Press in the test button for 2–6 s.
3 The lubrication cycle begins, and during the entire test cycle
Test button the control lamp will be flashing (2 s on / 2 s off) to indicate that
the function is activated.
4 If a fault should arise, an error code will be displayed after the
test cycle has been completed, see page 163.
5 The test cycle is ended automatically.
If the test lubrication cycle has been used to obtain an extra
lubrication cycle after a wash, the test button should be
pressed once more to lubricate the other main line.

Continuous test lubrication cycle

The pump carries out an unlimited number of lubrication cy-
cles, i.e. it continuously pumps out lubricant alternately via the
two main lines. This is used for bleeding the system of air.
1 Turn the ignition key to position 1 (running position).
2 Press the test button for more than 6 s.
3 The lubrication cycle begins, and during the entire test cycle
the control lamp will be flashing (0.2 s on / 0.2 s off) to indicate
that the function is activated.
4 If a fault should arise, an error code will be displayed after the
test cycle has been completed, see page 163.
5 End the test cycle by turning the ignition key to position 0. The
test cycle is not ended automatically.
 Basic preventive maintenance
Automatic greasing 165

Bleeding the system

A B The pump must not be activated for longer than five minutes.
1 Make sure that the lubricant reservoir has been filled up to the
max. mark.
2 Remove the plugs from the metering blocks (C) which are fur-
thest away from pump unit (D) in main lines (A) and (B).
3 Turn the ignition key to position 1 (running position).
4 Press the test button for more than six seconds, which will ini-
C tiate a continuous test cycle.
5 When lubricant, free from air, emerges from one of main lines,
the air bleeding is completed in that main line.
6 Turn the ignition key to the "0" position and install the plug.
A B D 7 Follow points 3–6 in order to bleed the other main line.
8 Test the system using the method “Single test lubrication cy-
cle”, see page 163.

Cleaning with high-pressure wash

L68946B Normally water cannot penetrate into the system. However, during
A Main line A a high-pressure wash the risk increases and the pump unit should
B Main line B be protected, as water, which has entered the system, does not
C Metering block disappear by itself, but could instead cause operating problems.
After a high-pressure wash a “Single test lubrication cycle” should
D Pump unit
be carried out to obtain additional lubrication.
 Basic preventive maintenance
166
 Specifications
Recommended lubricants 167

Specifications
Recommended lubricants
The viscosity indications are according to SAE J 300 MAR93.
Other mineral oils can be used if they conform to our viscosity rec-
ommendations and meet our quality requirements.
The approval of Volvo is required, if any other oil base quality (e.g.
biologically degradable oil) is to be used.
Recommended viscosity at varying ambient temperatures
°C –30 –20 –10 0 +10 +20 +30 +40 +50
Oil grade
°F –22 –4 +14 +32 +50 +68 +86 +104 +122
ENGINE Engine oil
VDS-3 or SAE 5W/30
Global DHD-1 + VDS-2 or SAE 10W/30
ACEA-E5 + VDS-2 or
SAE 15W/40
API CH-4 + VDS-2
SAE 30
SAE 40

AXLES Volvo WB 101

HUB REDUCTION For trade names and oil
GEARS requirements, see pages
175 and 190.

TRANSMISSION Dexron III

DROPBOX

L66 542A

HYDRAULIC SYS- Hydraulic oil

TEM Swedish norm SS 15 54 34 V 46/AV 46
Steering system V 68/AV 68
Brake system alternatively
Working hydraulics
international norm ISO VG 46 HV
Vickers 35 VQ/25 test ISO VG 68 HV
viscosity acc. to ISO 3448
class acc. to ISO 6743-4
L66 543 A

or alternatively

Engine oil SAE 10W/30

min. requirement API SF/CE SAE 15W/40
SAE 30
NOTE: As an alternative
there are also biologically
degradable hydraulic oils as
an additional choice. °C –30 –20 –10 0 +10 +20 +30 +40 +50
°F –22 –4 +14 +32 +50 +68 +86 +104 +122
 Specifications
168 Recommended lubricants

Grease
General lubrication points
Grease on lithium base with EP additives and consistency NLGI
class 2.
L66544A

NOTE: If the machine is provided with automatic greasing

system, other recommended lubricants apply, see page 162.
Rear axle pivot bearings
The following makes of grease for the rear axle pivot bearings are
recommended:
– Rubens HT2 (Q8)
– Chevron Ultra Duty No. 2
– Texaco Starplex HD2
– Almagard 3752

Cooling system
– Volvo original anti-freeze
– USA: Coolant norm ASTM D4985
L66545A

Fuel
Quality requirements: The fuel should at least meet the legal re-
quirements, and national and international standards for marketed
fuels, for example: EN590 (with nationally adapted temperature re-
quirements), ASTM D 975 No 1D and 2D, JIS KK 2204.
L66546A
Sulphur content: According to legal requirements (the sulphur
content must not exceed 0.3 percent by weight).
 Specifications
Capacities L150E 169

Capacities L150E
Capacities, litres (US gal) When changing
Engine incl. filter 39.5 litres (10.4 US gal)
Transmission incl. filter 45 litres (11.9 US gal)
Front axle 45 litres (11.9 US gal)
Rear axle 55 litres (14.5 US gal)
Hydraulic oil tank 156 litres (41.2 US gal)
Fuel tank 370 litres (97.7 US gal)
Cooling system 47 litres (12.4 US gal)

Carry out checks according to Service Programmes for the machine, see page 115.

Oil and fluid changes Hours

Engine 500*
Coolant 3000
Transmission, at the same time clean suction strainer 2000
Front and rear axles 1000/2000**
Hydraulic system (working hydraulics, brake system and steering 2000/4000***
system)

Filter changes
Engine, oil filters 500*
Engine, air cleaner (main filter) 1000
Engine, air cleaner (secondary filter) 2000
Engine, coolant filter 1000
Fuel filters 1000
Fuel system, breather filter 2000
Oil-bath precleaner, filter inserts 2000
Transmission, oil filter 2000
Transmission, breather filter 2000
Axle oil filter, cooling circuit (optional equipment) 2000
Drive axles, breather filter 2000
Hydraulic system, return oil filter 2000
Hydraulic system, breather filter 2000
Cab, ventilation filter (prefilter) 1000
Cab, ventilation filter (main filter) 2000****

*) Regarding conditions required if the interval between engine oil changes is to apply, see page 118.
**) If separate axle oil cooling (optional equipment) is installed, an interval of 2000 hours applies.
***) If the system is filled with hydraulic oil, an interval of 4000 hours applies.
****) In case of environment containing asbestos the filter should be replaced every 1000 hours.
 Specifications
170 Engine L150E

Engine L150E
Designation Volvo D10BLAE2
Flywheel output according to SAE J1349, net 199 kW at 26.7 r/s (1600 rpm)
Max. torque according to SAE J1349, net 1370 N m (1010 lbf ft) at 20 r/s (1200 rpm)
Number of cylinders 6
Cylinder bore 121 mm (4.764 in)
Stroke 140 mm (5.512 in)
Cylinder capacity, total 9.6 litres (586 in3)
Compression ratio 18.0:1
Valve clearance, warm and cold engine inlet valve 0.40 mm (0.016 in)
exhaust valve 0.70 mm (0.028 in)
Air cleaner Air cleaning in three steps
Cyclone cleaner – primary filter – secondary filter

Lubrication system
Oil pressure, warm engine, high idling 300–500 kPa (3–5 bar) (44–73 psi)
Oil pressure, warm engine, low idling min. 60 kPa (8.7 psi)

Fuel system
Type Hydraulically powered
Feed pressure 100–150 kPa (1–1.5 bar) (15–22 psi)
Intercooler Air/air

Cooling system
Type Closed system
Thermostat begins to open at 82 °C (180 °F)
Thermostat fully open at 92 °C (198 °F)
 Specifications
Electrical system L150E 171

Electrical system L150E

System voltage 24 V
Batteries 2 (connected in series)
Battery voltage 12 V
Battery capacity 2 x 140 Ah
Alternator 1540 W
Starter motor output 5.4 kW (7.3 hp)

Battery electrolyte density kg/dm3

Fully charged battery 1.275–1.285
The battery should be recharged at a 1.250
density of

Bulbs Watt Socket

Travel lights, asymmetrical 75/70 P 43t–38 (H4)
Parking lights, front 4 BA9s
Parking lights, rear 10 BA15s
Tail lights 10 BA15s
Stop lights 21 BA15s
Direction indicators, rear 21 BA15s
Direction indicators, front 21 BA15s
Side lights 5 SV 8.5
Centre instrument panel (20 pcs) 1.2 W2x4,6d
Cab light 10
Working lights, front halogen 70 PK 22 s (H3)
(optional)
Working lights, rear halogen 70 PK 22 s (H3)
(optional)
Guide light in switches 1.2 W2x4,6d
 Specifications
172 Electrical system L150E

Relays, L150E
IB

IA
RE101

FU50

FU52

FU54
FU55
RE803

RE802

FU59 RE801

RT801

L68236A

RE FUNCTION RE FUNCTION
1 Bucket positioner 12 15EA-feed
2 15A-feed 101 Automatic greasing system
3 Boom kick-out 202 Unloading starter inhibitor
4 15B-feed 601 Secondary steering pump
5 Intermittent wiper rear 602 Activation of lever steering (positioned in the
lever steering arm rest)
6 Intermittent wiper front 801 Air conditioning
7 Boom Suspension System – BSS 802 Air conditioning
8 Voltage starter inhibitor 803 Operator seat, air suspension
9 Starter inhibitor 2501 Preheating
10 Working lights (extra) RF 1 Flasher relay direction indicators
11 30-feed controlled by I-ECU RT801 Time relay air conditioning

IA and IB are service sockets.

 Specifications
Electrical system L150E 173

Fuses, L150E

FUSES IN THE ELECTRICAL DISTRIBUTION BOX (behind the operator seat)

FU A FUNCTION FU A FUNCTION
1 10 Bucket positioner and boom kick-out, floating 20 5 Stop lights, direction indicators
position and floating automatics, attachment
changing and locking, electrical control lever
lockout 4th hydraulic function
2 10 Boom Suspension System, single-acting lifting 21 5 Hour recorder, magnetisation of alternator, con-
function trol lamp charging, windscreen wiper and washer
rear, instrument lighting, instrument lighting serv-
ice display unit
3 10 Windscreen wiper and washer front, horn 22 10 Working lights radiator casing, control lamp
working lights
4 20 Cab fan, air conditioning 23 10 Voltage converter radio
5 5 Heating + air suspension for operator seat, 24 5 High beam right, control lamp high beam
automatic greasing, automatic temperature
control
6 5 Parking lights front right + rear left, side light 25 5 High beam left
front right, number plate lighting, guide light in
the switches
7 5 Parking lights front left + rear right, side light 26 10 Interior light, working lights cab front + front mud-
front left, instrument lighting, service socket IA guards + attachment, control lamp working lights
(instrument lighting service display unit)
8 15 Starter motor relay 27 15 Main fuse lighting
9 5 Hazard flashers 28 10 Working lights cab, rotating warning beacon
10 5 Voltage converter radio 29 10 Ignition switch voltage supply
11 5 Low beam right 30 5 Control lever carrier, brake pressure and brake
pressure charging, secondary steering, lever
steering, Boom Suspension System
12 5 Low beam left 31 5 Feed rear frame, pressure monitor raised fan
speed
13 10 Working lights front mudguards + attachment 32 5 Feed front frame, transmission, differential lock
(feed-back)
14 5 Preheating, gear selector + kick-down + direc- 50 5 –
tional gear steering column, transmission dis-
engagement, programme (mode) selector,
differential lock, service sockets IA and IB
15 10 Ignition-dependent voltage supply I-ECU + 52 10 Operator seat, air suspension
V-ECU, parking brake
16 10 Air conditioning 54 5 Operator seat, air suspension
17 10 Voltage supply I-ECU and V-ECU 55 5 –
18 20 Voltage supply E-ECU 59 10 Automatic greasing system, automatic tempera-
ture control
19 10 Cigarette lighter

FUSES IN THE FUSE BOX (positioned in the

FUSES ABOVE THE FUSE BOX
engine compartment)

FU A FUNCTION FU A FUNCTION

70 150 Main fuse, electrical distribution box FH1 5 Control lamp preheating

71 150 Secondary steering FH3 5 Control lamp secondary steering

72 150 Preheating FUSE BY THE BATTERY DISCONNECT

SWITCH
FH4 5 Constant ground for voltage converter
 Specifications
174 Power transmission L150E

Power transmission L150E

Transmission
Type Full power shift transmission
Designation HTE210
Torque converter Single stage
Torque multiplication 2.14:1
Number of gears 4 forward, 4 reverse
Gear-shifting system Electro-hydraulic

Axles
Type Fully floating drive shafts with hub reductions of the plan-
etary gear type
Designation front and rear AWB40
Differential lock On front axle
Type Dog clutch 100%
Operation Hydraulic via servo pressure

Wheel bolts
Tightening torque 600 ±50 N m (443 ±37 lbf ft)
 Specifications
Axle oils L150E 175

Axle oils L150E

Oil grade Volvo WB 101
Oil intended for axles with built-in wet brakes

Requirements

Transmission oil
Property Unit Test method
Volvo WB 101
Density kg/m3 To be stated ASTM D 1298
Flash point COC °C min. 180 ASTM D 92
Pour point °C min. –27 ASTM D 97
2
Viscosity at 40 °C mm /s (cSt) To be stated ASTM D 445
Viscosity at 100 °C mm2/s (cSt) min. 9.0 ASTM D 445
max. 12.5 DIN Draft 51350
Viscosity at 100 °C after shearing 30 mm2/s (cSt) min. 8.8 CEC-L-14-A-78
cycles
Viscosity at 20 °C mPas max. 3500 ASTM D 2602
Rust protection 24 h No rust ASTM D 665A
API class GL-4 ASTM STP-512A
Additive Lubrizol/Unizol
LZ 9990A
Solid particles code max. 18/13 ISO 4406

Examples of oils which meet the requirements according to the table on the next page

Other requirements
The oil should meet the requirements according to the following two norms:
FORD –- ESN – M2 C134 – D and JD JDQ95
The oil should have properties that counteract oxidation, corrosion and foaming, and be suitable for the stated
purpose.
 Specifications
176 Axle oils L150E

Oils for AWB axles made by Volvo Wheel Loaders AB

Examples of oils which meet the requirements according to the table on the previous page .

Oil company Trade name

Q8 Q8 T2200
MOBIL MOBILFLUID 424
ESSO TORQUE FLUID 56
SOLENE INDUSTRIAL LUBRICANT SOLENE TRACTELF CH-5
STATOIL TRANSWAY WB
AGROL AGROL HYBRAN
ARAL ARAL FLUID HGS
TEXACO TEXACO TEXTRAN TDH PREMIUM
VALVOLINE VALVOLINE UNITRAC
ELF TRACTELF CH-5
OMV AS OMV AUSTROMATIC IGB
FINA TRANSFLUID JD, 10W-30
AVIA HYDROFLUID JD, 10W-30
CALTEX TEXTRAN TDH PREMIUM
DELTA SPECIAL UTTO 170
TOTAL TRANSMISSION MP
PANOLIN AG PANOLIN HMO 324
PETROBAS LUBRAX UNITRACTOR

The following oils are approved provided the oil contains additive Lubrizol LZ9990A (Also appears under the
name Unizol)

Oil company Trade name

FUCHS FUCHS RENEGEAR HYDRA MC- ZF 20W/40
CASTROL CASTROL POWERTRANS
SHELL DONAX TD or FT/TD
BP BP TRACTRAN 9
BP HYDRAULIKÖLE TF-JD
ELF ELF TRACTELF BF12
 Specifications
Brakes / steering system L150E 177

Brakes / steering system L150E

Brakes
Service brakes, type Dual circuit, all-hydraulic, wet disc brake

Number of discs per wheel 1

Accumulator capacity Two at 1.0 litre (61 in3) and One at 0.5 litre (31 in3)
Friction area per wheel 1749 cm2 (271 in2)
Disc thickness, new 9.5 mm (0.374 in)
Disc thickness, min. 7.2 mm (0.283 in)

Parking brake
Type Electrically operated hydraulic disc brake
Disc thickness, new 4.8–4.9 mm (0.189–0.193 in)
Disc thickness, min. 4.5 mm (0.177 in)
Number of discs 7
Friction area 2583 cm2 (400 in2)

Steering system
Type Load-sensing, hydrostatic
Number of steering wheel revolu- 4.5 revolutions
tions, total
Steering arc ±37°

Oil pump
Type Axial piston pump, variable displacement
Working pressure 21.0 MPa (210 bar) (3046 psi)
Flow, max. 190 litres (50 US gal) per minute
Shock valve opening pressure at 28 ±1.0 MPa (4061 ±145psi)
high idling
 Specifications
178 Recommended air pressure L150E

Recommended air pressure L150E

Material handling Material handling
L150E loading work 10 km/h Loading/Carrying
Timber handling
25 km/h (15.5 mph)
(6.2 mph) 25 km/h (15.5 mph)
Tyres Front Rear Front Rear Front Rear
Bridgestone VL-2 kPa 300 250 300 250 375 250
26.5-25/32 PR psi 44 40 44 40 54 36
Goodyear HRL L3 kPa 300 200 300 200 Not Not
26.5-25/20 PR psi 43 29 43 29 allowed allowed
Goodyear HRL L4 kPa 300 200 300 200 Not Not
26.5-25/20 PR psi 43 29 43 29 allowed allowed
Goodyear HRL L5 kPa 300 200 300 200 Not Not
26.5-25/20 PR psi 43 29 43 29 allowed allowed
Bridgestone VMT kPa 350 250 350 250 425 250
26.5R25* psi 51 36 51 36 62 36
Goodyear RL2+ kPa 325 200 325 200 375 200
26.5R25* psi 47 29 47 29 54 29
Goodyear GP2B kPa 325 200 325 200 375 200
26.5R25* psi 47 29 47 29 54 29
Goodyear GP4B kPa 325 200 325 200 375 200
26.5R25* psi 47 29 47 29 54 29
Michelin XHA kPa 375 225 375 225 400 225
26.5R25* psi 54 33 54 33 58 33
Bridgestone VTS kPa 450 300 450 300 500 350
800/65R29* psi 65 44 65 44 71 51
Goodyear GP4D kPa 400 300 400 300 450 350
800/65R29* psi 58 44 58 44 65 51

– The recommended tyre pressures are based on the rated load for each handling case.

– In case of heavier loads, especially during timber handling or loading-carrying operations, a higher tyre pres-
sure is required. Contact the tyre manufacturer for information about which air pressure is the correct one for
the load to be handled and transported over a particular distance.

– If L4 or L5 tyres are used for loading-carrying operations, due attention must be paid to the transporting dis-
tances.
Radial tyres are to be preferred for loading-carrying operations, as the build-up of heat is less in this type of
tyre.
 Specifications
Cab L150E 179

Cab L150E
General
The cab is fitted on rubber elements, is insulated and has a flat floor with rubber mat.
Tested and approved as a protective cab and meets standards according to ISO3471-1994 and SAE 1040-
APR 88 (ROPS), ISO 3449-1992 (FOPS) and ISO 6055-1981 (protective roof for rider trucks).
Cab interior fittings and upholstery Fire retardant (fire resistant) meas-
ured according to ISO 3795-1989
Number of emergency exits 1 (right side window)
Heating and ventilation
The basic version of the loader is provided with a heating and ventilation system with defrosting for all windows
and the best possible air distribution (10 outlets). The cab fan is a double radial fan and it has four speeds. Air
conditioning is available as optional extra.
Operator seat
Height adjustment (rapid adjustment) 100 mm (4 in)
Longitudinal adjustment 160 mm (6.3 in)
Adjustment for driver weight 40–130 kg (88–287 lb)
Adjustment of back-rest, (adjustable back-rest inclination) 12°
Upholstery Fire resistant
Lap type seat belt with reel Yes
Vibration and sound information
Whole body vibrations
NOTE: Whole body vibrations generated by construction machines, are to a high degree influenced by
different factors, e.g. working methods, ground conditions and travelling speed selected by the opera-
tor. These factors are independent of the design of the machine. Therefore, it is not possible to state
one single value which is representative of the operator's exposure to whole body vibrations.
The values for whole body vibrations stated below, in accordance with European standard EN 474-1,
are not intended to be used to determine the operator's exposure to whole body vibrations when using
this machine.
Experience has shown that a correct design of the operator seat is the most efficient measure that can be
taken to reduce the whole body vibrations from a certain family of machines. The Volvo factory-fitted seat
meets the criteria according to EN ISO 7096:2000, which represent the most severe vibrations arising during
real working conditions. The seat in this machine has been tested applying power density spectrum class EM 3
and it has a transfer factor of SEAT <1.0, which means that whole body vibrations caused by the machine dur-
ing real working conditions and when it is used as intended may vary from <0.5 m/s 2 to a short-time level of
1.13 m/s2.
Sound information
Sound pressure level (LpA) at operator position See value on decal in the cab
Measuring is carried out according to 98/37/EC with applicable appen-
dices and measuring method according to ISO 6396.
Sound power level (LWA) around the machine See value on decal on the machine
Measuring is carried out according to 2000/14/EC with applicable
appendices and measuring method according to ISO 6395.
 Specifications
180 Hydraulic system L150E

Hydraulic system L150E

Type Servo-assisted of the ”open centre” type
Working pressure 26.0 ±0.5 MPa (260 ±5 bar) (3771 ±73 psi)
Shock valve for tilting function, forward 28.0 ±0.5 MPa (280 ±5 bar) (4061 ±73 psi)
Shock valve for tilting function, rearward 28.0 ±0.5 MPa (280 ±5 bar) (4061 ±73 psi)
Shock valve for lifting function 36.5 ±0.5 MPa (365 ±5 bar) (5294 ±73 psi)

Pump 1 Working hydraulics

Displacement 100 cm3 (6.1 in3)

Pump 2 Steering and brake systems and working hydraulics

Displacement 100 cm3 (6.1 in3)

Pump 3 Brake and cooling fan systems

Displacement 46 cm3 (2.8 in3)
 Specifications
Dimensional drawing L150E 181

Dimensional drawing L150E

Specifications and dimensions comply in applicable parts with ISO 7131, SAE J732, ISO 7546, SAE J742, ISO
5998, SAE J818, ISO 8313.
The data apply to a machine with 26.5 R25 L3 tyres.

*
O

P
Z L
M
K
N J
F
H
R R1 G

D 15G
U L68189A

L68187A
C
T E
B
A
S

Standard boom (lifting arms) Standard boom (lifting arms) Standard boom (lifting arms)
A * K 4350 mm (14 ft 3.3 in) T 54 mm (2.1 in)
B 7030 mm (23 ft 0.8 in) L * U 520 mm (1 ft 8.5 in)
C 3550 mm (11 ft 7.8 in) M * V *
D 450 mm (1 ft 5.7 in) N * X 2280 mm (7 ft 6 in)
E * O 59° Y 2950 mm (9 ft 8.1 in)
F 3580 mm (11 ft 8.9 in) Pmax. 49° Z 3500 mm (11 ft 5.8 in)
G 2130 mm (6 ft 11.9 in) R 44° a2 6780 mm (22 ft 3 in)
**
H * R1 48° a3 3380 mm (11 ft 1.1 in)
J 3960 mm (12 ft 11.9 in) S 66° a4 ±37°

*) See table on the next page

**) Carrying position SAE

Extended boom (lifting arms) Extended boom (lifting arms) Extended boom (lifting arms)
B 7550 mm (24 ft 3.2 in) Pmax. 49° Z 3970 mm (13 ft 0.3 in)
J 4530 mm (14 ft 10.3 in) R 47°
K 4920 mm (16 ft 1.7 in) S 61°
 Specifications
182 Machine capacity L150E

Machine capacity L150E

The maximum weight of the machine (incl. equipment and attachment) is 31000 kg (68343 lb).
Tyres 26.5 R25 L3

Standard buckets Rock and gravel handling Light Long boom

material
Direct- Direct- Direct- Bracket- Bracket- Direct- Direct- Direct-
mounted, mounted, mounted, mounted, mounted, mounted, mounted, mounted,
straight straight straight straight straight spade- straight with straight
Buckets with teeth with teeth with teeth without with teeth nose with teeth and without
and wear teeth with teeth and wear seg- teeth with
segments edge sav- wear seg- ments edge sav-
ers ments ers

Capacity 3.8 m3 4.0 m3 4,3 m3 4.0 m3 4.2 m3 3.5 m3 3.8 m3 6.8 m3 –

(5 yd3) (5.2 yd3) (5.6 yd3) (5.2 yd3) (5.5 yd3) (4.6 yd3) (5 yd3) (8.9 yd3)
Static tip- 17820 kg 17400 kg 17380 kg 16730 kg 16740 kg 17170 kg 16900 kg 16530 kg –3500 kg
ping load (39286 lb) (38360 lb) (39316 lb) (36883 lb) (36905 lb) (37853 lb) (37258 lb) (36442 lb) (–7716 lb)

Steered 15890 kg 15490 kg 15450 kg 14850 kg 14840 kg 15220 kg 14990 kg 14650 kg –3210 kg
35° (35031 lb) (34150 lb) (34061 lb) (32739 lb) (32717 lb) (33554 lb) (33047 lb) (32298 lb) (–7077 lb)

Fully 15680 kg 15270 kg 15230 kg 14640 kg 14630 kg 14990 kg 14770 kg 14440 kg –3170 kg
steered (34568 lb) (33665 lb) (33576 lb) (32276 lb) (32254 lb) (33047 lb) (32562 lb) (31835 lb) (–6989 lb)

Break-out 179.7 kN 170.6 kN 169.3 kN 165.5 kN 166.1 kN 164.7 kN 179.8 kN 128.1 kN –

force (40398 lbf) (38352 lbf) (38060 lbf) (37206 lbf) (37340 lbf) (37026 lbf) (40421 lbf) (28798 lbf)

A 8790 mm 8820 mm 8890 mm 8680 mm 8900 mm 8910 mm 8790 mm 9140 mm +520 mm

(28 ft 10.1 (28 ft 11.2 (29 ft 2.0 (28 ft 5.7 in) (29 ft 2.3 (29 ft 2.8 (28 ft 10.1 (29 ft 11.8 (+1 ft 8.5 in)
in) in) in) in) in) in) in)

E 1390 mm 1410 mm 1470 mm 1290 mm (4 1490 mm 1500 mm 1390 mm (4 1700 mm +6 mm

(4 ft 6.7 in) (4 ft 7.5 in) (4 ft 9.9 in) ft 2.8 in) (4 ft 10.7 (4 ft 11.1 in) ft 6.7 in) (5 ft 6.9 in) (+0.2 in)
in)
H***) 2910 mm 2890 mm 2850 mm 2990 mm 2850 mm 2830 mm 2900 mm 2630 mm +570 mm
(9 ft 6.6 in) (9 ft 5.8 in) (9 ft 4.2 in) (9 ft 9.7 in) (9 ft 4.2 in) (9 ft 3.4 in) (9 ft 6 in) (8 ft 7.5 in) 1 ft 10.4 in)

L 5940 mm 5940 mm 6050 mm 5940 mm 6050 mm 5950 mm 5910 mm 6100 mm +570 mm

(19 ft 5.9 (19 ft 5.9 (19 ft 10.2 (19 ft 5.9 in) (19 ft 10.2 (19 ft 6.3 (19 ft 4.7 in) (20 ft 0.2 in) (1 ft 10.4 in)
in) in) in) in) in)
M***) 1360 mm 1350 mm 1430 mm 1270 mm 1470 mm 1440 mm 1340 mm 1540 mm –32 mm
(4 ft 5.5 in) (4 ft 5.1 in) (4 ft 8.3 in) 4 ft 2.0 in) (4 ft 9.9 in) (4 ft 8.7 in) (4 ft 4.8 in) (5 ft 0.6 in) (1.3 in)

N 1900 mm 1880 mm 1940 mm 1830 mm 1950 mm 1940 mm 1870 mm 1930 mm +450 mm

(6 ft 2.8 in) (6 ft 2.0 in) (6 ft 4.4 in) (6 ft 0 in) (6 ft 4.8 in) (6 ft 4.4 in) (6 ft 1.6 in) (6 ft 4.0 in) (1 ft 5.7 in)

V 3000 mm 3000 mm 3000 mm 3200 mm 3230 mm 3230 mm 3230 mm 3200 mm –

(9 ft 10.1 (9 ft 10.1 (9 ft 10.1 (10 ft 6.0 in) (10 ft 7.2 (10 ft 7.2 (10 ft 7.2 in) (10 ft 6.0 in)
in) in) in) in) in)
a1 turning 14540 mm 14540 mm 14580 mm 14670 mm 14810 mm 14810 mm 14750 mm 14890 mm –
radius (47 ft 8.4 (47 ft 8.4 (47 ft 10.0 (48 ft 1.6 in) (48 ft 7.1 (48 ft 7.1 (48 ft 4.7 in) (48 ft 10.2
in) in) in) in) in) in)

Machine 23020 kg 23210 kg 23340 kg 23510 kg 23670 kg 23690 kg 23630 kg 23660 kg +300 kg
weight (50750 lb) (51169 lb) (51456 lb) (51831 lb) (52183 lb) (52227 lb) (52095 lb) (52161 lb) (661 lb)

*) with L5-tyres
***) Measured to tip of bucket tooth or edge savers. Dumping height to edge of bucket (acc. to SAE)
+ approx. 200 mm (8 in). Measured at an dumping angle of 45°.
 Specifications
Timber grapple L150E 183

Timber grapple L150E

Timber grapple (with attachment bracket)
Attachment Bracket-mounted
Tyres 800/65 R29
A 3.1 m2 (33.4 ft2)

20G
45G
I

H
20G K
B
J D

E
C
L
G
M L67074A

B 3670 mm (12 ft 0.4 in) F 1630 mm (5 ft 3.4 in) J 3080 mm (10 ft 1.3 in)
C 2090 mm (6 ft 8.6 in) G 2910 mm (9 ft 5.5 in) K 3340 mm (10 ft 11.5 in)
D 2970 mm (9 ft 7.4 in) H 4990 mm (16 ft 3.7 in) L 2290 mm (7 ft 5.1 in)
E 1630 mm (5 ft 3.4 in) I 7270 mm (23 ft 10.2 in) M 9690 mm (31 9.5 ft in)
 Specifications
184 Capacities L180E

Capacities L180E
Capacities, litres (US gal) When changing
Engine incl. filter 48 litres (12.7 US gal)
Transmission incl. filter 45 litres (11.9 US gal)
Front axle 45 litres (11.9 US gal)
Rear axle 55 litres (14.5 US gal)
Hydraulic oil tank 156 litres (41.2 US gal)
Fuel tank 370 litres (97.7 US gal)
Cooling system 70 litres (18.5 US gal)

Carry out checks according to Service Programmes for the machine, see page 115.

Oil and fluid changes Hours

Engine 500*
Coolant 3000
Transmission, at the same time clean suction strainer 2000
Front and rear axles 1000/2000**
Hydraulic system (working hydraulics, brake system and steering 2000/4000***
system)

Filter changes
Engine, oil filters 500*
Engine, air cleaner (main filter) 1000
Engine, air cleaner (secondary filter) 2000
Engine, coolant filter 1000
Fuel filters 1000
Fuel system, breather filter 2000
Oil-bath precleaner, filter inserts 2000
Transmission, oil filter 2000
Transmission, breather filter 2000
Axle oil filter, cooling circuit (optional equipment) 2000
Drive axles, breather filter 2000
Hydraulic system, return oil filter 2000
Hydraulic system, breather filter 2000
Cab, ventilation filter (prefilter) 1000
Cab, ventilation filter (main filter) 2000****

*) Regarding conditions required if the interval between engine oil changes is to apply, see page 118.
**) If separate axle oil cooling (optional equipment) is installed, an interval of 2000 hours applies.
***) If the system is filled with hydraulic oil, an interval of 4000 hours applies.
****) In case of environment containing asbestos the filter should be replaced every 1000 hours.
 Specifications
Engine L180E 185

Engine L180E
Designation Volvo D12CLCE2
Flywheel output according to SAE 221 kW at 23.3 r/s (1400 rpm)
J1349, net
Max. torque according to SAE 1690 N m (1246 lbf ft) at 20 r/s (1200 rpm)
J1349, net

Number of cylinders 6
Cylinder bore 131 mm (5.157 in)
Stroke 150 mm (5.906 in)
Cylinder capacity, total 12.13 litres (740 in3)
Compression ratio 18.5:1
Valve clearance, warm and cold inlet valve 0.20 mm (0.008 in)
engine
outlet valve 0.50 mm (0.020 in)
Air cleaner Air cleaning in three steps
Cyclone cleaner – primary filter – secondary filter

Lubrication system
Oil pressure, warm engine, high 300–600 kPa (3.0–6.0 bar) (44–87 psi)
idling
Oil pressure, warm engine, low idling min. 70 kPa (10 psi)

Fuel system
Type Hydraulically powered
Feed pressure 300–350 kPa (3.0–3.5 bar) (44–51 psi)
Intercooler Air/air
Cooling system
Type Closed
Thermostat begins to open at 82 °C (180 °F)
Thermostat fully open at 91 °C (197 °F)
 Specifications
186 Electrical system L180E

Electrical system L180E

System voltage 24 V
Batteries 2 (connected in series)
Battery voltage 12 V
Battery capacity 2 x 170 Ah
Alternator 1540 W
Starter motor output 7.0 kW (9.5 hp)

Battery electrolyte density kg/dm3

Fully charged battery 1.275–1.285
The battery should be recharged at a 1.250
density of

Bulbs Watt Socket

Travel lights, asymmetrical 75/70 P 43t–38 (H4)
Parking lights, front 4 BA9s
Parking lights, rear 10 BA15s
Tail lights 10 BA15s
Stop lights 21 BA15s
Direction indicators, rear 21 BA15s
Direction indicators, front 21 BA15s
Side lights 5 SV 8.5
Centre instrument panel (20 pcs) 20 x 1.2 W2x4,6d
Cab light 10
Working lights, front halogen 70 PK 22 s (H3)
(optional)
Working lights, rear halogen 70 PK 22 s (H3)
(optional)
Guide light in switches 1.2 W2x4,6d

Fuses
Type Blade fuse
Current rating 20 A
Current rating 15 A
Current rating 10 A
Current rating 5A
 Specifications
Electrical system L180E 187

Relays, L180E
IB

IA
RE101

FU50

FU52

FU54
FU55
RE803

RE802

FU59 RE801

RT801

L68236A

RE FUNCTION RE FUNCTION
1 Bucket positioner 12 15EA-feed
2 15A-feed 101 Automatic greasing system
3 Boom kick-out 202 Unloading starter inhibitor
4 15B-feed 601 Secondary steering pump
5 Intermittent wiper rear 602 Activation of lever steering (positioned in the
lever steering arm rest)
6 Intermittent wiper front 801 Air conditioning
7 Boom Suspension System – BSS 802 Air conditioning
8 Voltage to starter inhibitor 803 Operator seat, air suspension
9 Starter inhibitor 2501 Preheating
10 Working lights (extra) RF 1 Flasher relay for direction indicators
11 30-feed controlled by I-ECU RT801 Time relay for air conditioning

IA and IB are service sockets.

 Specifications
188 Electrical system L180E

Fuses, L180E

FUSES IN THE ELECTRICAL DISTRIBUTION BOX (behind the operator seat)

FU A FUNCTION FU A FUNCTION
1 10 Bucket positioner and boom kick-out, floating 20 5 Stop lights, direction indicators
position and floating automatics, attachment
changing and locking, electrical control lever
lockout 4th hydraulic function
2 10 Boom Suspension System, single-acting lifting 21 5 Hour recorder, magnetisation of alternator, con-
function trol lamp charging, windscreen wiper and washer
rear, instrument lighting, instrument lighting serv-
ice display unit
3 10 Windscreen wiper and washer front, horn 22 10 Working lights radiator casing, control lamp
working lights
4 20 Cab fan, air conditioning 23 10 Voltage converter radio
5 5 Heating + air suspension for operator seat, 24 5 High beam right, control lamp high beam
automatic greasing, automatic temperature
control
6 5 Parking lights front right + rear left, side light 25 5 High beam left
front right, number plate lighting, guide light in
the switches
7 5 Parking lights front left + rear right, side light 26 10 Interior light, working lights cab front + front mud-
front left, instrument lighting, service socket IA guards + attachment, control lamp working lights
(instrument lighting service display unit)
8 15 Starter motor relay 27 15 Main fuse, lighting
9 5 Hazard flashers 28 10 Working lights cab, rotating warning beacon
10 5 Voltage converter radio 29 10 Ignition switch voltage supply
11 5 Low beam right 30 5 Control lever carrier, brake pressure and brake
pressure charging, secondary steering, lever
steering, Boom Suspension System
12 5 Low beam left 31 5 Feed rear frame, pressure monitor raised fan
speed
13 10 Working lights front mudguards + attachment 32 5 Feed front frame, transmission, differential lock
(feed-back)
14 5 Preheating, gear selector + kick-down + direc- 50 5 –
tional gear steering column, transmission dis-
engagement, programme (mode) selector,
differential lock, service sockets IA and IB
15 10 Ignition-dependent voltage supply I-ECU + 52 10 Operator seat, air suspension
V-ECU, parking brake

FUSES IN THE FUSE BOX (positioned in the

FUSES ABOVE THE FUSE BOX
engine compartment)

FU A FUNCTION FU A FUNCTION

70 150 Main fuse, electrical distribution box FH1 5 Control lamp preheating

71 150 Secondary steering FH3 5 Control lamp secondary steering

72 150 Preheating FUSE BY THE BATTERY DISCONNECT

SWITCH
73 60 Starter motor FH4 5 Constant ground for voltage converter
 Specifications
Power transmission L180E 189

Power transmission L180E

Transmission
Type Full power shift transmission
Designation HTE220
Torque converter Single stage
Torque multiplication 2.04:1
Number of gears 4 forward, 4 reverse
Gear-shifting system Electro-hydraulic

Axles
Type Fully floating drive shafts with hub reductions of the plan-
etary gear type
Designation front and rear AWB40
Differential lock On front axle
Type Dog clutch 100%
Operation Hydraulic via servo pressure

Wheel bolts
Tightening torque, front and rear axles 600 ±50 N m (443 ±37 lbf ft)
 Specifications
190 Axle oils L180E

Axle oils L180E

Oil grade Volvo WB 101
Oil intended for axles with built-in wet brakes

Requirements

Transmission oil
Test method
Property Unit Volvo WB 101
Density kg/m3 To be stated ASTM D 1298
Flash point COC °C min. 180 ASTM D 92
Pour point °C min. –27 ASTM D 97
2
Viscosity at 40 °C mm /s (cSt) To be stated ASTM D 445
Viscosity at 100 °C mm2 /s (cSt) min. 9.0 ASTM D 445
max. 12.5 DIN Draft 51350
Viscosity at 100 °C after shearing 30 mm2/s (cSt) min. 8.8 CEC-L-14-A-78
cycles
Viscosity at 20 °C mPas max. 3500 ASTM D 2602
Rust protection 24 h No rust ASTM D 665A
API class GL-4 ASTM STP-512A
Lubrizol/Unizol
Additive LZ 9990A
Solid particles code max. 18/13 ISO 4406

Examples of oils which meet the requirements according to the table on the next page

Other requirements
The oil should meet the requirements according to the following two norms:
FORD –- ESN – M2 C134 – D and JD JDQ95
The oil should have properties that counteract oxidation, corrosion and foaming, and be suitable for the stated
purpose.
 Specifications
Axle oils L180E 191

Oils for AWB axles made by Volvo Wheel Loaders AB

Examples of oils which meet the requirements according to the table on the previous page .

Oil company Trade name

Q8 Q8 T2200
MOBIL MOBILFLUID 424
ESSO TORQUE FLUID 56
SOLENE INDUSTRIAL LUBRICANT SOLENE TRACTELF CH-5
STATOIL TRANSWAY HB
AGROL AGROL HYBRAN
ARAL ARAL FLUID HGS
TEXACO TEXACO TEXTRAN TDH PREMIUM
VALVOLINE VALVOLINE UNITRAC
ELF TRACTELF CH-5
OMV AS OMV AUSTROMATIC IGB
FINA TRANSFLUID JD, 10W-30
AVIA HYDROFLUID JD, 10W-30
CALTEX TEXTRAN TDH PREMIUM
DELTA SPECIAL UTTO 170
TOTAL TRANSMISSION MP
PANOLIN AG PANOLIN HMO 324
PETROBAS LUBRAX UNITRACTOR

The following oils are approved only if the oil contains additive Lubrizol LZ9990A. (Also appears under the
name of Unizol.)

Oil company Trade name

FUCHS FUCHS RENOGEAR HYDRA MC- ZF 20W/40
CASTROL CASTROL POWERTRANS
SHELL DONAX TD or FT/TD
BP BP TRACTRAN 9
BP HYDRAULIKÖLE TF-JD
ELF ELF TRACTELF BF12
 Specifications
192 Brakes / steering system L180E

Brakes / steering system L180E

Brakes
Service brakes, type Dual circuit, all-hydraulic, wet disc brake

Number of discs per wheel 1

Accumulator capacity Two at 1.0 litre (61 in3) and One at 0.5 litre (31 in3)
Friction area per wheel 1749 cm2 (271 in3)
Disc thickness, new 9.5 mm (0.374 in)
Disc thickness, min. 7.2 mm (0.283 in)

Parking brake
Type Electrically operated hydraulic disc brake
Disc thickness, new 4.8–4.9 mm (0.189–0.193 in)
Disc thickness, min. 4.5 mm (0.177 in)
Number of discs 7
Friction area 2583 cm2 (400 in2)

Steering system
Type Load-sensing, hydrostatic
Number of steering wheel revolu- 4.5 revolutions
tions, total
Steering arc ±37°

Oil pump
Type Axial piston pump, variable displacement
Working pressure 21.0 MPa (210 bar) (3046 psi)
Flow, max. 190 litres (50.2 US gal) per minute
Shock valve opening pressure at 28.0 ±1.0 MPa (4061 ±145 psi)
high idling
 Specifications
Recommended air pressure L180E 193

Recommended air pressure L180E

Material handling Material handling

L180E loading work 10 km/h Loading/Carrying 25
Timber handling
25 km/h (15.5 mph)
(6.2 mph) km/h (15.5 mph)
Tyres Front Rear Front Rear Front Rear
Bridgestone VL-2 kPa 350 250 350 250 475 250
26.5-25/32 PR psi 51 36 51 36 69 36
Goodyear HRL L4 kPa 350 200 350 200 Not Not
26.5-25/24 PR psi 51 29 51 29 allowed allowed
Goodyear HRL L5 kPa 350 200 350 200 Not Not
26.5-25/24 PR psi 51 29 51 29 allowed allowed
Bridgestone VMT kPa 425 250 425 250 525 250
26.5R25* psi 62 36 62 36 78 36
Goodyear RL2+ kPa 425 250 425 250 450 250
26.5R25* psi 62 36 62 36 65 36
Goodyear GP2B kPa 425 250 425 250 450 250
26.5R25* psi 62 36 62 36 65 36
Goodyear GP4B kPa 425 250 425 250 450 250
26.5R25* psi 62 36 62 36 65 36
Michelin XHA kPa 425 225 425 225 425 225
26.5R25* psi 62 33 62 33 62 33
Bridgestone VTS kPa 450 300 450 300 500 350
800/65R29* psi 65 43 65 43 73 51
Goodyear GP4D kPa 450 300 450 300 500 350
800/65R29* psi 65 43 65 43 73 51
Michelin XLD kPa 400 300 400 300 450 300
800/65R29* psi 58 43 58 43 65 43

– The recommended tyre pressures are based on the rated load for each handling case.

– In case of heavier loads, especially during timber handling or loading-carrying operations, a higher tyre pres-
sure is required. Contact the tyre manufacturer for information about which air pressure is the correct one for
the load to be handled and transported over a particular distance.

– If L4 or L5 tyres are used for loading-carrying operations, due attention must be paid to the transporting dis-
tances.
Radial tyres are to be preferred for loading-carrying operations, as the build-up of heat is less in this type of
tyre.
 Specifications
194 Cab L180E

Cab L180E
General
The cab is fitted on rubber elements, is insulated and has a flat floor with rubber mat.
Tested and approved as a protective cab and meets standards according to ISO3471-1994 and SAE 1040-
APR 88 (ROPS), ISO 3449-1992 (FOPS) and ISO 6055-1981 (protective roof for rider trucks).
Cab interior fittings and upholstery Fire retardant (fire resistant) measured according to ISO
3795-1989
Number of emergency exits 1 (right side window)
Heating and ventilation
The basic version of the loader is provided with a heating and ventilation system with defrosting for all windows
and the best possible air distribution (10 outlets). The cab fan is a double radial fan and it has four speeds. Air
conditioning is available as optional extra.
Operator seat
Height adjustment (rapid adjustment) 100 mm (4 in)
Longitudinal adjustment 160 mm (6.3 in)
Adjustment for driver weight 40–130 kg (88–287 lb)
Adjustment of back-rest, (adjustable back-rest incli- 12°
nation)
Upholstery Fire resistant
Lap type seat belt with reel Yes
Vibration and sound information
Whole body vibrations
NOTE: Whole body vibrations generated by construction machines, are to a high degree influenced by
different factors, e.g. working methods, ground conditions and travelling speed selected by the opera-
tor. These factors are independent of the design of the machine. Therefore, it is not possible to state
one single value which is representative of the operator's exposure to whole body vibrations.
The values for whole body vibrations stated below, in accordance with European standard EN 474-1,
are not intended to be used to determine the operator's exposure to whole body vibrations when using
this machine.
Experience has shown that a correct design of the operator seat is the most efficient measure that can be
taken to reduce the whole body vibrations from a certain family of machines. The Volvo factory-fitted seat
meets the criteria according to EN ISO 7096:2000. which represent the most severe vibrations arising during
real working conditions. The seat in this machine has been tested applying power density spectrum class EM
3 and it has a transfer factor of SEAT <1.0. which means that whole body vibrations caused by the machine
during real working conditions and when it is used as intended may vary from <0.5 m/s 2 to a short-time level of
1.13 m/s2.
Sound information
Sound pressure level (LpA) at operator position See value on decal in the cab
Measuring is carried out according to 98/37/EC
with applicable appendices and measuring method
according to ISO 6396.
Sound power level (LWA) around the machine See value on decal on the machine
Measuring is carried out according to 2000/14/EC
with applicable appendices and measuring method
according to ISO 6395.
 Specifications
Hydraulic system L180E 195

Hydraulic system L180E

Type Servo-assisted of the ”open centre” type
Working pressure 26.0 ±0.5 MPa (260 ±5 bar) (3771 ±73 psi)
Shock valve for tilting function, for- 28.0 ±0.5 MPa (280 ±5 bar) (4061 ±73 psi)
ward
Shock valve for tilting function, rear- 28.0 ±0.5 MPa (280 ±5 bar) (4061 ±73 psi)
ward
Shock valve for lifting function 36.5 ±0.5 MPa (365 ±5 bar) (5294 ±73 psi)

Pump 1 Working hydraulics

Displacement 130 cm3 (7.9 in3)

Pump 2 Steering and brake systems and working hydraulics

Displacement 100 cm3 (6.1 in3)

Pump 3 Brake and cooling fan systems

Displacement 46 cm3 (2.8 in3)
 Specifications
196 Dimensional drawing L180E

Dimensional drawing L180E

Specifications and dimensions comply in applicable parts with ISO 7131, SAE J732, ISO 7546, SAE J742, ISO
5998, SAE J818, ISO 8313.
The data apply to a machine with 26.5 R25 L3 tyres.

*
O

P
Z L
M
K
N J
F
H
R R1 G

D 15G
U
L68187A
C
T E
L68189A
B
A
S

Standard boom (lifting arms) Standard boom (lifting arms) Standard boom (lifting arms)
A * K 4480 mm (14 ft 7.0 in) T 113 mm (4.4 in)
B 7180 mm (23 ft 5.6 in) L * U 560 mm (1 ft 10.0 in)
C 3550 mm (11 ft 7.8 in) M * V *
D 440 mm (1 ft 4.4 in) N * X 2280 mm (7 ft 6 in)
E * O 57° Y 2950 mm (9 ft 8.1 in)
F 3580 mm (11 ft 7.5 in) Pmax. 49° Z 3170 mm (10 ft 4.0 in)
G 2134 mm (7 ft) R 44° a2 6780 mm (22 ft 3 in)
**
H * R1 48° a3 3830 mm (12 ft 7 in)
J 4070 mm (13 ft 3.5 in) S 66° a4 ±37°

*) See table on the next page

**) Carrying position SAE

Extended boom (lifting arms) Extended boom (lifting arms) Extended boom (lifting arms)
B 7640 mm (25 ft 0.8 in) Pmax. 49° S 63°
J 4580 mm (15 ft 0.3 in) R 48° Z 3540 mm (11 ft 7.4 in)
**
K 4980 mm (16 ft 4.1 in) R1 48°
 Specifications
Machine capacity L180E 197

Machine capacity L180E

The maximum weight of the machine (incl. equipment and attachment) is 31000 kg (68343 lb).
Tyres 26.5 R25 L3

Standard buckets Rock and Light Long boom

gravel material
handling
Direct- Direct- Direct- Direct- Direct- Bracket- Direct- Direct-
mounted, mounted, mounted, mounted, mounted, mounted, mounted, mounted,
straight straight straight straight straight straight spade-nose straight
with teeth with teeth with teeth without without without with teeth without
Buckets and wear teeth with teeth with teeth with teeth with
segments edge sav- edge sav- edge sav- edge sav-
ers ers ers ers

Capacity 4.4 m3 4.4 m3 4.6 m3 4.6 m3 4.8 m3 4.8 m3 4.1 m3 7.8 m3 –

(5.8 yd3) (5.8 yd3) (6.0 yd3) (6.0 yd3) (6.3 yd3) (6.3 yd3) (5.4 yd3) (10.2 yd3)
Static tip- 20460 kg 20970 kg 20770 kg 20700 kg 19760 kg 20530 kg 21480 kg 19580 kg –3600 kg
ping load (45107 lb) (46231 lb) (45790 lb) (45636 lb) (43563 lb) (45261 lb) (47355 lb) (43166 lb) (–7937 lb)

Steered 18110 kg 18590 kg 18410 kg 18340 kg 17460 kg 18190 kg 19030 kg 17270 kg –3270 kg
35° (39926 lb) (40983 lb) (40587 lb) (40433 lb) (38493 lb) (40102 lb) (41954 lb) (38074 lb) (7209 lb)

Fully 17840 kg 18320 kg 18140 kg 18070 kg 17200 kg 17930 kg 18750 kg 17010 kg –3230 kg
steered (39330 lb) (40389 lb) (39991 lb) (39837 lb) (37919 lb) (39529 lb) (41337 lb) (37501 lb) (–7121 lb)

Break-out 204.8 kN 215.7 kN 206.5 kN 204.9 kN 185.8 kN 196.6 kN 193.2 kN 150.6 kN –

force (46041 lbf) (48491 lbf) (46423 lbf) (46063 lbf) (41770 lbf) (44197 lbf) (43433 lbf) (33856 lbf)

A 9000 mm 8990 mm 9060 mm 8790 mm 8950 mm 8860 mm 9150 mm 9340 mm +450 mm

(29 ft 6.3 (29 ft 5.9 (29 ft 8.7 (28 ft 10.1 (29 ft 4.4 (29 ft 0.8 (30 ft 0.2 in) (30 ft 7.7 in) (1 ft 5.7 in)
in) in) in) in) in) in)
E 1530 mm 1520 mm 1580 mm 1340 mm 1480 mm 1400 mm 1660 mm 1840 mm –
(5 ft 0.3 in) (4 ft 11.8 (5 ft 2.2 in) (4 ft 4.8 in) (4 ft 10.3 (4 ft 7.1 in) (5 ft 5.4 in) (6 ft 0.4 in)
in) in)
H***) 2990 mm 3000 mm 2950 mm 3120 mm 3040 mm 3080 mm 2910 mm 2700 mm +510 mm
(9 ft 9.7 in) (9 ft 10.1 (9 ft 8.1 in) (10 ft 2.8 in) (9 ft 11.7 (10 ft 1.3 (9 ft 6.6 in) (8 ft 10.3 in) 1 ft 8.1 in)
in) in) in)
L 6140 mm 6180 mm 6190 mm 6180 mm 6240 mm 6190 mm 6320 mm 6310 mm +490 mm
(20 ft 1.7 (20 ft 3.3 (20 ft 3.7 (20 ft 3.3 in) (20 ft 5.7 (20 ft 3.7 (20 ft 8.8 in) (20 ft 8.4 in) (1 ft 7.3 in)
in) in) in) in) in)
M***) 1400 mm 1400 mm 1450 mm 1230 mm 1380 mm 1280 mm 1530 mm 1580 mm +20 mm
(4 ft 7.1 in) (4 ft 7.1 in) (4 ft 9.1 in) (4 ft 0.4 in) (4 ft 6.3 in) (4 ft 2.4 in) (5 ft 0.2 in) (5 ft 2.2 in) (+0.8 in)

N 2010 mm 2020 mm 2050 mm 1910 mm 1980 mm 1930 mm 2100 mm 2030 mm +420 mm

(6 ft 7.1 in) (6 ft 7.5 in) (6 ft 8.7 in) (6 ft 3.2 in) (6 ft 6.0 in) (6 ft 4.0 in) (6 ft 10.7 in) (6 ft 9.9 in) (1 ft 4.5 in)

V 3200 mm 3230 mm 3230 mm 3200 mm 3200 mm 3200 mm 3230 mm 3400 mm –

(10 ft 6.0 (10 ft 7.2 (10 ft 7.2 (10 ft 6.0 in) (10 ft 6.0 (10 ft 6.0 (10 ft 7.2 in) (11 ft 1.9 in)
in) in) in) in) in)
a1 14850 mm 14880 mm 14910 mm 14750 mm 14820 mm 14780 mm 14970 mm 15210 mm –
(48 ft 8.6 (48 ft 9.8 (48 ft 11.0 (48 ft 4.7 in) (48 ft 7.5 (48 ft 5.9 (49 ft 1.4 in) (49 ft 10.8
in) in) in) in) in) in)

Machine 26540 kg 26350 kg 26400 kg 26430 kg 26790 kg 26480 kg 27650 kg 26830 kg + 210 kg
weight (58511 lb) (58092 lb) (58202 lb) (58268 lb) (59061 lb) (58378 lb) (60958 lb) (59150 lb) (+463 lb)

*) with L5-tyres
***) Measured to tip of bucket tooth or edge savers. Dumping height to edge of bucket (acc. to SAE) + approx.
200 mm (8 in). Measured at an dumping angle of 45°.
 Specifications
198 Timber grapple L180E

Timber grapple L180E

Timber grapple (with attachment bracket)
Attachment Bracket-mounted
Tyres 800/65 R29
A 3.1 m2 (33.4 ft2)

20G
45G
I

H
20G K
B
J D

E
C
L
G
M L67074A

B 3810 mm (12 ft 6.0 in) F 1630 mm (5 ft 4.2 in) J 3080 mm (10 ft 1.3 in)
C 2090 mm (6 ft 10.3 in) G 2990 mm (9 ft 9.7 in) K 3340 mm (10 ft 11.5 in)
D 3110 mm (10 ft 2.4 in) H 5130 mm (16 ft 10.0 in) L 2410 mm (7 ft 10.9 in)
E 1630 mm (5 ft 4.2 in) I 7400 mm (24 ft 3.3 in) M 9810 mm (32 ft 2.2 in)
 Alphabetical index
199

Alphabetical index Equipment........................................................................ 6

Evaporator ................................................................... 146
Accidents .......................................................................85 Excavating ..................................................................... 92
Accumulators, releasing pressure..................................90 Fire prevention measures ............................................ 110
Adjusting heating and ventilation ...................................61 Fluor rubber ................................................................. 112
Adjusting lift height.........................................................56 FOPS and ROPS............................................................. 6
Adjusting tilting rearwards ..............................................56 Foreword.......................................................................... 1
Air cleaner ....................................................................125 Front and rear axles..................................................... 138
Air conditioning (optional equipment)...........................145 Front left instrument panel ............................................. 33
Air filter, alternator (optional equipment) ......................134 Front right instrument panel........................................... 24
Alarm texts .....................................................................44 Fuel filters .................................................................... 120
Alphabetical index ........................................................199 Fuel system ................................................................. 120
Alternator .....................................................................133 Fuel system, air bleeding, L150E ................................ 121
Arm rest .........................................................................59 Fuel system, air bleeding, L180E ................................ 122
Arrival and Delivery Inspection.....................................115 Fuel tank ...................................................................... 120
Attaching and disconnecting attachments .....................87 Fuel.............................................................................. 168
Attachments ...................................................................86 Fuses, L150E............................................................... 173
Automatic greasing ......................................................160 Fuses, L180E............................................................... 188
Automatic Power Shift (APS II) ......................................72 Gear shifting .................................................................. 72
Axle oils L150E ............................................................175 Getting stuck................................................................ 106
Axle oils L180E ............................................................190 Gravel and heap loading................................................ 92
Axles, changing oil .......................................................138 Grease ......................................................................... 168
Axles, oil cooling (optional equipment).........................139 Greasing bearings ....................................................... 150
Basic preventive maintenance .....................................115 Headlamps, adjusting .................................................. 135
Batteries.......................................................................131 Hydraulic system L150E .................................. 6, 147, 180
Batteries, charging .......................................................132 Hydraulic system L180E .................................. 6, 147, 195
Batteries, rules .............................................................131 Hydraulic system, breather filter .................................. 148
Battery disconnect switch ............................................131 Hydraulic system, changing oil .................................... 147
Before service read......................................................108 Hydraulic system, checking oil level ............................ 147
Boom kick-out and bucket positioner .............................56 Hydraulic system, return oil filter.................................. 148
Brake system ...........................................................6, 140 Hydraulically powered, rotating attachments ............... 102
Brake test .......................................................................77 Identification numbers...................................................... 2
Brakes / steering system L150E ..................................177 Information and warning plates / decals .......................... 9
Brakes / steering system L180E ..................................192 Initial display .................................................................. 35
Braking ...........................................................................77 Instrument panels .......................................................... 17
Breather filter, fuel system ...........................................123 Intended use .................................................................... 5
Breather filters, axles ...................................................139 Keyboard for the display unit ......................................... 36
Bucket operation ............................................................91 Kick-down function......................................................... 74
Buckets ..........................................................................91 Lap type seat belt, checking and maintenance.............. 58
Buzzer ............................................................................28 Levelling......................................................................... 94
Cab L150E .......................................................6, 142, 179 Lever steering, CDC (optional equipment) .................... 75
Cab L180E .......................................................6, 142, 194 Lifting attachments....................................................... 105
Cab, ventilation filters...................................................142 Loading ........................................................................ 100
Capacities L150E .........................................................169 Lubrication and service chart, L150E .......................... 152
Capacities L180E .........................................................184 Lubrication and service chart, L180E .......................... 156
CE marking, EMC directive ..............................................7 Lubrication of propeller shafts...................................... 139
Centre instrument panel.................................................26 Machine capacity L150E.............................................. 182
Choosing bucket ............................................................91 Machine capacity L180E.............................................. 197
Climate control system...................................................60 Machine information ...................................................... 37
Combi-forks....................................................................99 Machine operator safety ................................................ 67
Compressor .................................................................146 Manual gear shifting ...................................................... 73
Condenser ...................................................................146 Material handling arm .................................................. 100
Controls..........................................................................49 Measures before operating............................................ 70
Coolant filter .................................................................130 Oil-bath precleaner (optional equipment) .................... 126
Coolant.........................................................................127 Operating information .................................................... 35
Coolant, changing ........................................................128 Operating instructions.................................................... 65
Coolant, checking ........................................................128 Operating techniques..................................................... 85
Cooling system .................................................... 127, 168 Operating with a load................................................... 101
Delivery Instructions.....................................................115 Operating with material handling arm .......................... 101
Dimensional drawing L150E ........................................181 Operating with pallet forks ............................................. 98
Dimensional drawing L180E ........................................196 Operating with whole trunks .......................................... 97
Display unit ....................................................................35 Operator comfort............................................................ 57
Dumping load .................................................................94 Operator duties .............................................................. 66
Electrical system L150E...................................5, 131, 171 Operator seat................................................................. 57
Electrical system L180E...................................5, 131, 186 Operator seat, lubrication ............................................ 144
Engine L150E ..................................................5, 118, 170 Other attachments ....................................................... 105
Engine L180E ..................................................5, 118, 185 Other controls ................................................................ 49
Engine oil filters, replacing ...........................................119 Pallet forks ..................................................................... 98
Engine oil, changing.....................................................118 Parking brake, mechanical release................................ 83
Engine oil, checking .....................................................118 Parking........................................................................... 80
Engine retarding / downshifting......................................74 Positioning of machine................................................. 100
Engine, air cleaner .......................................................125 Positioning of transporting vehicle ................................. 94
 Alphabetical index
200

Power transmission L150E ......................................6, 174

Power transmission L180E ......................................6, 189
Presentation.....................................................................5
Pressure release ............................................................89
Primary filter, maintenance and replacement...............125
Product plates ..................................................................8
Radiator, cleaning ........................................................130
Rear vision system (optional equipment) .......................63
Recommended air pressure L150E .............................178
Recommended air pressure L180E .............................193
Recommended lubricants ............................................167
Recovering/towing .........................................................81
Refrigerant (R134a) .....................................................145
Relays and fuses .........................................................134
Relays, L150E..............................................................172
Relays, L180E..............................................................187
Right instrument panel ...................................................18
Rock loading ..................................................................93
Rotating attachments ...................................................102
Rubber and plastics .....................................................113
Running-in instructions ..................................................65
Safety regulations ............................................................1
Safety rules when operating ..........................................66
Safety when servicing ..................................................107
Secondary filter ............................................................125
Separate attachment locking .........................................88
Service points, L150E ..................................................116
Service points, L180E ..................................................117
Service position............................................................107
Service Programmes ...................................................115
Service schedule..........................................................151
Settings via the keyboard...............................................42
Signalling diagram .......................................................103
Slinging ........................................................................104
Specifications...............................................................167
Starting engine ...............................................................71
Starting with booster batteries .....................................132
Steering system ...............................................................6
Steering wheel adjustment (optional equipment) ...........59
Steering..........................................................................75
Stopping machine ..........................................................79
Suction strainer ............................................................137
Symbol key ..................................................................150
Table of Contents.............................................................3
The USA Federal Clean Air Act .....................................14
Timber grapple L150E ...........................................95, 183
Timber grapple L180E ...........................................95, 198
Transmission oil level, checking...................................136
Transmission................................................................136
Transmission, breather filter.........................................137
Transmission, changing oil ..........................................136
Transmission, replacing oil filter...................................137
Transporting load (loading – carrying) ...........................93
Transporting machine ....................................................84
Travelling and operating (working) on a public road ......69
Turbocharger ...............................................................124
Tyres ............................................................................149
Washer fluid reservoir, front and rear windows............126
Water trap ....................................................................123
What to do if the machine gets stuck ...........................106
Wheel bolts, check-tightening ......................................149
Window catch.................................................................62
Working on painted surfaces .......................................112
Working with timber grapples.........................................96
Working within dangerous areas....................................68

Ref no VOE 2126696832 English

Printed in Sweden CST