Volvo L150G Wheel Loader Service Repair Manual Instant Download.pdf

Service Information
Document Title: Function Group: Information Type: Date:
Component locations 200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
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Component locations
Engine, component positions
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
Remote oil filter housing
Preheater, inlet manifold
Compressor
Fuel pump
External oil trap
E-ECU
AC compressor
Alternator

Figure 2
1.
2.
Turbocharger with wastegate valve
Starter motor

Service Information
Component locations 200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
Component locations
Engine, component positions
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Preheater, inlet manifold
Alternator
AC compressor
Air pump for Exhaust Aftertreatment System
Crankcase ventilation, separator
E-ECU
Fuel pump
Compressor
Remote oil filter housing

Figure 2
1.
2.
3.
4.
5.
Exhaust Gas Recirculation (EGR), description
Starter motor
EGR-cooler
EGR venturi tube
Variable geometry turbine (VGT) turbocharger

Service Information
Engine, description 200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
Engine, description
Engines D11F, D13F, and D16F are straight six-cylinder, four-stroke, direct-injected diesel engines. Engines D13F and D16F
are equipped with a single turbocharger with wastegate and engine D11F has a turbocharger without wastegate. They have
charge-air cooling with mechanically actuated electronically controlled unit injectors, controlled by the EMS-system.
The engines have a one-piece cylinder head with four valves per cylinder and a single overhead camshaft. Rear-mounted
timing gear results in a shorter engine and lighter drivetrain installation. Engine brake for Articulated Hauler; VEB+ (EPG,
Exhaust Pressure Governor, and VCB, Volvo Compression Brake).
For more information, see:





220 Lubrication system, description
230 Fuel system, description
250 Inlet and exhaust system, description
255 Turbocharger, description
260 Cooling system, description
For Articulated Haulers:


253 Auxiliary brake (engine braking), description
253 Exhaust pressure governor
The cylinders are numbered in sequence, starting farthest from the flywheel. Ignition order: 1-5-3-6-2-4. The engine's
rotational direction is counter-clockwise, seen from the flywheel.
Engine identification

Figure 1
Identification plates, D13F
Identification plate 1
A label located on the valve cover showing the engine's component ID-number, serial number, manufacturing site, engine
part number, and engine build date, as well as their bar codes. Manufacturing sites:
A = Skövde, Sweden
E = Curitiba, Brazil
F = Flen, Sweden
L = Lyon, France
The engine's serial number, part number, and manufacturing site are stamped into the engine's cylinder block.
The hardware component number of the Engine Control Unit (ECU) is located on a label on the back of the ECU.
The certification label is located on the valve cover as well as the machine's frame.
Automatic Engine Shutdown
This is a function used to automatically shut down the engine after idling for a certain time. The operator is informed and
has the opportunity to cancel the function within one minute, either by increasing the engine speed, shifting gear, or by
activating the hand throttle.
Engine protection
The ECU contains functionality designed to protect the engine from damage during extreme operating conditions or from
further damage when an essential engine component fails. There are several proactive functions, and different applications
have different functions activated. The ones that can be activated are:








High coolant temperature
High intake manifold air pressure
High intake manifold air temperature
High oil temperature
Low oil pressure
Low coolant level
High crankcase pressure
High ECU temperature
Various protective actions such as warning lights, engine torque reduction, engine speed limitation, and vehicle speed
limitation may be taken when the above functions reach dangerous levels that may damage the engine. In order to always
allow the operator to move a machine away from an unsafe situation, there is a delay of at least 30 seconds before the
protective actions (such as forced idle and forced shutdown) are activated after a Key-ON. If the engine has been forced to
shutdown or forced to idle due to an active engine protection function, the operator can obtain a 30 second delay by
powering down the EMS with a Key-OFF for 7 seconds and then a Key-ON (the EMS is powered down by the Vehicle-ECU
(V-ECU) after the ignition key has been in its OFF position for approx. 7 seconds). In addition to the above protective
functions, other software functions could request engine protection, such as:





High Altitude (ensures that high compressor discharge temperature is never reached)
Turbo OverSpeed
Low Coolant Temp
Crank Sensor Failure
Gear Ratio
Warning lights
There are two levels for warning lights, an amber caution light and a red stop light.


The amber light indicates a warning situation
The red light indicates that the vehicle must be stopped.
Engine torque limitation
The engine torque can be limited by the engine protection function. Engine torque limitation is active until the parameter

has reached a safe level or until the EMS is powered down.
Forced Idle
The engine can be forced to idle speed by the engine protection function. Forced idle is active until conditions triggering the
problem are back within normal working range or the EMS is powered down.
Engine Shutdown
The engine can be forced to shut down after conditions have reached levels that may cause engine failure and the machine
speed is below a specified value.
Machine Speed and Engine Speed Limits
The engine protection function can limit the speed of the vehicle and/or the engine's rpm.
Levels of engine protection
Available proactive functions depend not only on the application but also on what level of protection has been activated for
the specific machine. Two levels of engine protection are offered, the standard level is Basic protection and the optional level
Extended protection. The general difference between basic and extended engine protection is that no active actions such as
forced idle and forced shutdown will be taken in basic engine protection (with the exception of crankcase pressure that can
cause shutdown in either setup). Warnings will be given to the operator regardless of engine protection level.
Parameters









(ATJ) Injector cylinder 1, calibration
(ATK) Injector cylinder 2, calibration
(ATL) Injector cylinder 3, calibration
(ATM) Injector cylinder 4, calibration
(ATN) Injector cylinder 5, calibration
(ATO) Injector cylinder 6, calibration
(FAU) Automatic engine shut off
(FAV) Automatic engine shut off, time
(YA) Idle speed, setting
Supplementary information
 200 Component locations
Function check
 17030-3 Parameter, programming
Diagnostics
Detailed information about the following relevant warnings and error codes is available under the diagnostics tab.
Component Control unit Message ID
EF2117 (ART)
PPID55 (WLO, EXC)
MID128 PPID55
SE2202
FX1006 (WLO)
MID128 PID175
SE2507
FX1007 (WLO)
MID128 PID105
SE2203 MID128 PID100

Service Information
Engine, description 200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
Engine, description
Engines D11H, D13H, and D16H are straight six-cylinder, four-stroke, direct-injected diesel engines. They are equipped with
a single variable geometry turbocharger (VGT) and feature cooled external exhaust gas recirculation (EGR). They have
charge-air cooling with mechanically actuated electronically controlled unit injectors, controlled by the EMS-system.
The engines have a one-piece cylinder head with four valves per cylinder and a single overhead camshaft. Rear-mounted
timing gear results in a shorter engine and lighter drivetrain installation. The engine brake for articulated haulers, VEB7, does
not have the additional Exhaust Pressure Governor, EPG. Sufficient exhaust back-pressure will be controlled via the VGT.
For more information, see:







220 Lubrication system, description
230 Fuel system, description
250 Inlet and exhaust system, description
254 Exhaust Aftertreatment System, description
255 Turbocharger, description
260 Cooling system, description
293 Exhaust Gas Recirculation (EGR), description
For Articulated Haulers:
 253 Auxiliary brake (engine braking), description
The cylinders are numbered in sequence, starting farthest from the flywheel. Ignition order: 1-5-3-6-2-4. The engine's
rotational direction is counter-clockwise, seen from the flywheel.
Engine identification

Figure 1
Identification plates, D13H
A label located on the valve cover showing the engine's component ID-number, serial number, manufacturing site, engine
part number, and engine build date, as well as their bar codes. Manufacturing sites:
A = Skövde, Sweden
E = Curitiba, Brazil
F = Flen, Sweden
L = Lyon, France
The engine's serial number, part number, and manufacturing site are stamped into the engine's cylinder block.
The hardware component number of the Engine Control Unit (ECU) is located on a label on the back of the ECU.
The certification label is located on the valve cover as well as the machine's frame.
Automatic Engine Shutdown
This is a function used to automatically shut down the engine after idling for a certain time. The operator is informed and
has the opportunity to cancel the function within one minute, either by increasing the engine speed, shifting gear, or by
activating the hand throttle.
Engine protection
The ECU contains functionality designed to protect the engine from damage during extreme operating conditions or from
further damage when an essential engine component fails. There are several proactive functions, and different applications
have different functions activated. The ones that can be activated are:
 High coolant temperature
















High intake manifold air pressure
High intake manifold air temperature
High oil temperature
Low oil pressure
Low coolant level
High temperature of cooled EGR exhausts after the EGR-cooler
High crankcase pressure
Variable Geometry Turbo valve and position error
High temperature of Smart Remote Actuator
High compressor charge-air temperature (calculated)
High soot load
High differential pressure across Diesel Particulate Filter (DPF)
High exhaust temperature
High ECU temperature
High DPF temperature
Various protective actions such as warning lights, engine torque reduction, engine speed limitation, and vehicle speed
limitation may be taken when the above functions reach dangerous levels that may damage the engine. In order to always
allow the operator to move a machine away from an unsafe situation, there is a delay of at least 30 seconds before the
protective actions (such as forced idle and forced shutdown) are activated after a Key-ON. If the engine has been forced to
shutdown or forced to idle due to an active engine protection function, the operator can obtain a 30 second delay by
powering down the EMS with a Key-OFF for 7 seconds and then a Key-ON (the EMS is powered down by the Vehicle-ECU
(V-ECU) after the ignition key has been in its OFF position for approx. 7 seconds). In addition to the above protective
functions, other software functions could request engine protection, such as:






High Altitude (ensures that high compressor charge-air temperature is never reached)
Turbo OverSpeed
Low Coolant Temp
Crank Sensor Failure
Gear Ratio
Regeneration
Warning lights
There are two levels for warning lights, an amber caution light and a red stop light.


The amber light indicates a warning situation
The red light indicates that the vehicle must be stopped.
Engine torque limitation
The engine torque can be limited by the engine protection function. Engine torque limitation is active until the parameter
has reached a safe level or until the EMS is powered down.
Forced Idle
The engine can be forced to idle speed by the engine protection function. Forced idle is active until conditions triggering the
problem are back within normal working range or the EMS is powered down.
Engine Shutdown
The engine can be forced to shut down after conditions have reached levels that may cause engine failure and the machine
speed is below a specified value.
Machine Speed and Engine Speed Limits
The engine protection function can limit the speed of the vehicle and/or the engine's rpm.
Levels of engine protection
Available proactive functions depend not only on the application but also on what level of protection has been activated for
the specific machine. Two levels of engine protection are offered, the standard level is Basic protection and the optional level
Extended protection. The general difference between basic and extended engine protection is that no active actions such as
forced idle and forced shutdown will be taken in basic engine protection (with the exception of crankcase pressure that can
cause shutdown in either setup). Warnings will be given to the operator regardless of engine protection level.
Parameters


(FAU) Automatic engine shut off
(FAV) Automatic engine shut off, time








(JVL) Injector cylinder 1, calibration E3 Glitch Trim
(JVM) Injector cylinder 2, calibration E3 Glitch Trim
(JVN) Injector cylinder 3, calibration E3 Glitch Trim
(JVO) Injector cylinder 4, calibration E3 Glitch Trim
(JVP) Injector cylinder 5, calibration E3 Glitch Trim
(JVQ) Injector cylinder 6, calibration E3 Glitch Trim
(YA) Idle speed, setting
Supplementary information
 200 Component locations
Function check
 17030-3 Parameter, programming
Diagnostics
Detailed information about the following relevant warnings and error codes is available under the diagnostics tab.
Component Control unit Message ID
EF2112 (ART)
PID404 (EXC, WLO)
MID128 PID404
EF2117 (ART)
PPID55 (WLO, EXC)
MID128 PPID55
EF2127 (ART)
PPID89 (EXC, WLO)
MID128 PPID89
EF2515 (ART)
PSID28 (WLO, EXC)
MID128 PSID28
EF2525 (ART)
PID173 (EXC)
SE2510 (WLO)
MID128 PID173
SE2202
FX1006 (WLO)
MID128 PID175
SE2507
FX1007 (WLO)
MID128 PID105
MO2501 MID128 SID27
PPID326 (WLO, EXC) MID128 PPID326
SE2519 MID128 PID81

Service Information
E-ECU, MID 128, changing
non-programmed ECU
200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
E-ECU, MID 128, changing non-programmed ECU
Op nbr 200-068
VCADS Pro VCADS Pro Service Tool
88890180 Interface
88890027 Cable
1. Place the machine in service position 1, see .
191 Service position
2. Connect VCADS Pro and start operation 28423-3 MID 128 ECU, programming.
3. Turn off the voltage with the battery disconnector.
4. Remove the engine cover on the right side.
5. Disconnect and move aside the pipe for the crankcase ventilation.
Figure 1
1.
2.
E-ECU
Crankcase ventilation
6. Disconnect the cable clamps for the alternator cable.
7. Unplug the connectors from the E-ECU and loosen the cable harness clamps.
8. Disconnect the cooling coil from the E-ECU and move the cooling coil aside.
9. Replace the E-ECU.
10. Install the cooling circuit.

11. Plug in the connectors and install the cable harness clamps.
12. Install the cable clamps for the alternator cable.
13. Install the pipe for the crankcase ventilation.
14. Install the engine cover.
15. Turn on the voltage with the battery disconnector.
16. Finish the VCADS Pro operation 28423-3 MID 128 ECU, programming.
17. Start the machine and check that there are no error messages.
18. Run a service regeneration to ensure the actual soot level in the DPF, see .
254 Perform a service regeneration
19. Restore the machine.

Service Information
E-ECU, MID 128, changing
pre-programmed ECU
200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
E-ECU, MID 128, changing pre-programmed ECU
Op nbr 200-070
VCADS Pro VCADS Pro Service Tool
88890180 Interface
88890027 Cable
2. The new control unit has basically adjusted parameters for the machine. Connect VCADS Pro and read out
customer parameters from the old control unit with operation 17030-3 Parameter, programming. If it is possible to
read out customer parameters from the old control unit, save them on the job card.
3. Turn off the voltage with the battery disconnector.
4. Remove the engine cover on the right side.
5. Disconnect the pipe for crankcase ventilation.
Figure 1
1.
2.
E-ECU
Crankcase ventilation
6. Disconnect the cable clamps for the alternator cable.
7. Unplug the connectors from the E-ECU and loosen the cable harness clamps.
8. Disconnect the cooling coil from the E-ECU and move the cooling coil aside.
9. Replace the E-ECU.

10. Install the cooling circuit.
11. Plug in the connectors and install the cable harness clamps.
12. Install the cable clamps for the alternator cable.
13. Install the pipe for the crankcase ventilation.
14. Install the engine cover.
15. Turn on the voltage with the battery disconnector.
16. If customer parameters have been read out from the old control unit, they should be compared with the
parameters in the new control unit.



Connect VCADS Pro and run operation 17030-3 Parameter, programming. Save all read parameters to job
card.
Compare the parameter settings on the job cards.
Run the operation 17030-3 Parameter, programming and change customer parameters according to job
cards for the old control unit.
17. Start the machine and check that there are no error messages.
18. Run a service regeneration to ensure the actual soot level in the DPF, see .
254 Perform a service regeneration
19. Restore the machine.

Service Information
VCADS Pro, Operations 200 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
VCADS Pro, Operations
The following VCADS Pro operations are available for function group 2. Operations used when changing or working on
components are mandatory.
Tests
Operation Application
20046-3 Read out engine information The operation is used to read out the engine emission and engine certificate
information when requested by the customer or other interested parties.
21006-3 Cylinder compression, test Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
This test indicates if there is any deviation in compression in any cylinder in
relation to the other cylinders.
As a first check this operation is both easy and fast to perform instead of an
actual compression test.
23016-3 Cylinder balancing, test Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings
This test indicates if any of the injectors deviates too much in fuel injection
so that the engine's characteristics deteriorate.
23017-3 Feed pressure, inspection Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
23712-3 Injectors shut off, manual Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
25410-3 Air pump exhaust aftertreatment,
test
Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
25411-3 Burner exhaust aftertreatment, test Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
25412-3 Components ASU, test This sub-test is used to check the functions of the atomizer air valve, the
main air valve, the fuel shut-off valve, and the fuel pump.
25457-3 Diesel Particulate Filter Service
Regeneration
Used when the soot load is above 1.7.
See 254 Exhaust Aftertreatment System, description
Before starting service regeneration, check the differential pressure across
the diesel particle filter so that it is within stated value according to the
service information. This is to make sure that the DPF will not be damaged
by the service regeneration.
After the service regeneration and when the exhaust temperature has
stabilized to a normal level, check the differential pressure across the DPF
again so that it is within stated value according to the service information.
This is to determine that the filter has been regenerated correctly and that it
is not clogged with ash.
25537-3 Variable geometry turbo function
test
When there is a suspicion of malfunction and/or in case of abnormal values/
readings.
26385-3 Reversible cooling fan, test When there is a suspicion of malfunction and/or in case of abnormal values/
readings.
27102-3 Accelerator pedal, test In case of abnormal values/readings.
28407-3 Sensor values, monitoring When there is a suspicion of malfunction and/or in case of abnormal values/
readings.

28420-3 Flywheel and camshaft signal, test Used when there is suspicion of defective signals or incorrectly connected
sensor.
29332-3 Exhaust gas circulation, function
test
Used when there is a suspicion of malfunction and/or in case of abnormal
values/readings.
Calibrations
25536-3 Variable geometry turbo, calibration When changing actuator. See 255 Actuator, variable turbocharger, replacing
Programming
25801-3 MID 233 Control unit, programming When changing ACM or only reprogramming. See
254 ACM, replacing, non-programmed
28423-3 MID 128 ECU, programming When changing ACM or only reprogramming. See
200 E-ECU, MID 128, changing non-programmed ECU

Service Information
Engine, removing 210 Service Information 2014/5/14
Profile:
WLO, L150G [GB]
Engine, removing
Op nbr 210-070
This operation also includes required tools and times for applicable parts of the following operations:
1.
2.
3.
173 Coolant, changing
173 Engine oil, draining
2. Turn off the current with the battery disconnector.
3. Drain the coolant, see .
173 Coolant, changing
4. Drain the engine oil, see .
173 Engine oil, draining
5. Drain the compressed air tank by pressing in the valve on the tank's underside.
Figure 1
NOTE!
Mark all hose and cable connections before they are disconnected, for easier assembly later on. Plug all open
connections.
6. Disconnect the transmission oil hose from the flywheel housing. To avoid oil leaks, plug the hose and fasten it to

the transmission with a tensioning strap or similar.
Figure 2
1.
2.
3.
4.
5.
6.
7.
Sensor on charge-air pipe
Oil dipstick
Stay
Induction air pipe between air cleaner and air inlet
Fuel and oil filter bracket
Clamping of radiator pipe
Coolant hoses

8.
9.
10.
11.
Breather filter for fuel tank
Oil and coolant drain point
Fuel connection, grouping point
Transmission oil hose
7. Remove the clamp that holds the oil drain hose.
8. Remove the lower right plastic part of the partition wall.
9. Unplug the sensor and remove the charge-air pipe. Protect open connections from dust and particles. Remove the
cable clamps. Disconnect the bracket for the oil dipstick from the partition wall. Remove the oil filter housing,
together with the oil filters, from the fuel and oil filter bracket. Remove the attaching bolts for the fuel and oil filter
bracket and move it aside, together with the fuel filters. Remove the stays for the partition wall. Disconnect the
breather hose for the fuel tank from the breather filter. Disconnect the clamps for the lower radiator pipe from the
partition wall.
NOTE!
Install the horizontal stay again in its right bracket. This is to enable use of the handrail.
Figure 3
1.
2.
3.
4.
Attaching bolts for DPF
Sensor, induction air pipe
Cable harness
Attaching bolts, stay and handrail

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Please download this document
first, and then click the above link
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5.
6.
7.
8.
9.
Charge-air pipe
Coolant hose for transmission oil cooler
Engine heater cable [ 1] 
Upper and lower coolant hoses
Connector, lower plastic part of partition wall
10. Unplug the connector and remove the lower plastic part from the partition wall.
11. Remove the clamps and disconnect the cable harness from the partition wall. Disconnect the connector for the
pressure sensor from the induction air pipe. Remove the attaching bolts for the induction air pipe from the
partition wall. Remove the charge-air pipe. Protect all open connections from dust and particles. Disconnect the
upper and lower coolant hoses from the partition wall. Disconnect the breather hose (which passes through the
partition wall) from the expansion tank and the wall. Remove the attaching bolts for the stays for the partition wall.
NOTE!
Install the horizontal stay again in its right bracket. This is to enable use of the handrail.
12. Disconnect the induction air pipe from the air cleaner and air inlet. (The air cleaner remains on the partition wall.)
Remove the induction air pipe.
13. Connect a lifting device and lift away the partition wall. Weight: approx. 80 kg (177 lbs)
Figure 4
14. Remove the hoses that are connected to the lower coolant pipe.Remove the lower coolant pipe.
WARNING
Do not disconnect or loosen connections for the air conditioning unit (AC). Risk of gas leakage.
15. Remove the belt guard. Disconnect the oil filler pipe and the connector from the AC-compressor. Remove the drive
belt for the AC-compressor. Disconnect the AC-compressor from the engine and fasten it to the side of the engine
with cable ties or similar.
Figure 5
16. Disconnect the coolant hose for the transmission oil cooler from the engine. Disconnect the engine heater cable

Volvo L150G Wheel Loader Service Repair Manual Instant Download.pdf

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