Volvo L45G (4 liter) technical manual

1. Volvo L45G service repair manual Download VOLVO WHEEL LOADERS L45G, L50G 8.6-9.9 t (19,026-21,804 lbs) 98-114 hp DOWNLOAD COMPLETE MANUAL

2. Volvo L45G service repair manual Download A passion for performance. At Volvo Construction Equipment, we’re not just coming along for the ride. Developing products and services that raise productivity – we are confident we can lower costs and increase profits for industry experts. Part of the Volvo Group, we are passionate about innovative solutions to help you work smarter – not harder. Helping you to do more Doing more with less is a trademark of Volvo Construction Equipment. High productivity has long been married to low energy consumption, ease of use and durability. When it comes to lowering life-cycle costs, Volvo is in a class of its own. The strength of our dealer network is enhanced with extensive individualized product and product support training at our state- of-the-art Technical Training Center in Asheville and through hands-on training. At our nearby 80-acre Product Demonstration Center, visitors operate equipment from our entire product line under a variety of simulated working conditions. Both facilities are in year-round use by our dealers and customers – more than 2,000 visit each year. Building the best starts right here. The products designed and manufactured by Volvo Construction Equipment have their beginnings at the most advanced Research & Design centers in the industry. Volvo CE machines are designed in 11 R&D centers and produced in 15 manufacturing facilities across the world. Designed to fit your needs There is a lot riding on creating solutions that are suited to the particular needs of different industry applications. Innovation often involves high technology – but it doesn’t always have to. Some of our best ideas have been simple, based on a clear and deep understanding of our customers’ working lives. The major R&D center and manufacturing plant in the Americas is located in Shippensburg, Pennsylvania. This facility has been in operation for over 30 years and – with its recently added 200,000 sq. ft. expansion – now covers 570,000 sq. ft. on an 80 acre campus. Dedicated work teams and highly advanced technologies and techniques using the Volvo Production System ensure continuous quality improvements, labor savings and cost control to reach the high quality that our customers have come to expect from Volvo. You learn a lot in 175 years Over the years, Volvo has advanced solutions that have revolutionized the use of construction equipment. No other name speaks Safety louder than Volvo. Protecting operators, those around them and minimizing our environmental impact are traditional values that continue to shape our product design philosophy. We’re on your side We back the Volvo brand with the best people. Volvo is truly a global enterprise, one that is on standby to support customers quickly and efficiently – wherever they are. We have a passion for performance. A strong, dedicated, capable dealer network. Our dealers are strategically located throughout North America to provide the equipment you need and the parts and service support you demand for a productive and profitable operation. 2

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4. Introducing the best all-rounder. Volvo proudly introduces the L45G and L50G wheel loaders, built to perform on every site. The compact design enables easy maneuverability into small spaces, while Volvo’s innovative TP linkage gives you the benefits of two machines in one. Experience the versatility for yourself. Load-sensing hydraulics Load-sensing hydraulics deliver power to hydraulic functions only when it’s needed, without unnecessary oil pumping, for lower fuel consumption and more sensitivity in load handling. High lifting force Pilot-controlled valves A careful balance between lifting and tractive forces provides highly effective bucket penetration for all types of digging conditions. Smooth and precise pilot-operated hydraulics enable the operator to easily control attachments with minimum effort and high precision in all applications. 4 Volvo L45G service repair manual Download

5. Latest engine technology. Volvo machines work hard on your job site, not on the environment. Power and efficiency are at the heart of Volvo’s engine, which uses the latest technology to meet Tier 4 Interim/Stage IIIB regulations and reduce emissions as you operate. Environmentally responsible and powerful; that’s Volvo. Engine cooling fan Reduce emissions on the move Reduce maintenance with the reversible engine cooling fan. The automatic fan blows air back through the cooling pack to remove debris drawn into the radiator and only operates when needed to save fuel. Volvo’s regeneration system works to reduce emissions without interrupting operation. Particles collected during filter cleaning are oxidized and transformed into non-toxic CO2 every 6-10 hours. Diesel Particulate Filter (DPF) Efficient eco pedal New to Tier 4, the Diesel Particulate Filter (DPF) traps and temporarily holds exhaust particulates (soot) as the machine operates, which are later incinerated inside the DPF during the regeneration process. Avoid excessive fuel use with Volvo’s new eco pedal, which encourages operators to apply the appropriate amount of pressure (push-back) on the throttle pedal, reducing fuel consumption. 5 Volvo L45G service repair manual Download

6. Small size: big talent. Efficient eco pedal The eco pedal encourages operators to apply the appropriate amount of pressure (push-back) on the throttle pedal, reducing fuel consumption. Patented TP linkage Volvo’s unique Torque Parallel linkage combines Z-Bar and Parallel linkage in one for high breakout torque and parallel movement through the entire lifting range. Steering Load-sensing hydrostatic steering system served from variable displacement pump. Excellent steering performance is maintained even at low engine speed. At the same time fuel consumption is reduced. Hydraulic attachment bracket The Volvo hydraulic attachment bracket enables quick attachment changes for more flexibility on site. Load-sensing hydraulics Load-sensing hydraulics deliver power to hydraulic functions only when it’s needed, lowering fuel consumption. Volvo attachments Volvo’s range of high quality attachments are perfectly matched to the machine’s linkage, hydraulics and driveline to work as one unit and increase productivity. Optimized driveline Engine, transmission and axles work in perfect harmony with the hydraulics and steering for superb quality, performance and reliability. 6

7. Industry-leading cab Adjustable steering wheel, seat and armrest, easily located controls and excellent all-round visibility for the perfect operator environment. Analysis software Maintain machine uptime by using Volvo’s diagnostic computer-based analysis software: MATRIS and VCADS Pro. CareTrack Volvo’s telematics system guides machine owners towards optimized productivity and their next service – remotely. Maintain your uptime The transverse mounted engine design provides easy access to all service points under the engine hood, for quick completion of maintenance checks. Tier 4 Interim/Stage IIIB engine Powerful, fuel efficient Volvo engine with V-ACT technology for high torque at low engine speeds. Engineered to meet Tier 4 Interim/ Stage IIIB emissions requirements. Differential lock Select the differential lock to transfer 100% power to all wheels and reduce tire slippage for maximum traction on soft and slippery ground. 7

8. Compact your service time. Daily service and maintenance checks have never been easier thanks to the new compact design. Lift the engine hood to quickly access key components from the radiator to the hydraulic filters and use Volvo diagnostic tools to alert when service is required. Volvo keeps you working for longer. Engine air filter The dual element air filter is located in the engine compartment for full protection of the engine. Maintenance-free axle cradle Analysis software The rear axle cradle with integrated oscillating bearings are lubricated with the axle oil and protected by proven seals, saving you hours of maintenance time. Maintain machine uptime by using Volvo’s diagnostic computer- based analysis software. MATRIS assesses operational data from the machine’s electronic control unit (ECU), while VCADS Pro can adjust machine function according to results. 8

9. Strength to Support You and Your Business. The day you receive your new Volvo Wheel Loader is just the start of your working relationship with Volvo. From service and maintenance products to a wide range of options and attachments – Volvo has a comprehensive aftermarket portfolio to continuously add value to your business. Attachments - Providing customers with a wide variety of attachments keep your machine working and open up new job opportunities. Customer Support Agreements - Gives you peace of mind by reducing total ownership costs, maximizing uptime, and distributing maintenance and major repair costs. Volvo designed and built your machines, so no-one knows how to keep them working in top condition more than us. When it comes to your machine, our Volvo trained technicians are the experts. Our technicians work with industry leading diagnostic tools and techniques, using only Genuine Volvo Parts to deliver the highest levels of quality and service. Talk to your Volvo dealer about how genuine Volvo services can best provide the service and maintenance plan that is the right fit for you and your business. State-of-the-art machines require state-of-the-art support and your Volvo dealer can provide a catalogue of services designed to get the most out of your machine, helping you maximise uptime, productivity and residual value. Your Volvo dealer can provide a number of sophisticated support offers, including: Service plans ranging from routine wear inspections, through to comprehensive maintenance and repair agreements. Analysis and diagnostics to help you understand how your machine is running, highlight potential maintenance issues and identify where performance can be improved. Eco Operator training courses can help your operators work towards a safer, more productive and fuel efficient performance. CareTrack Volvo’s state-of-the-art telematics system works with our exclusive machine tracking info system, MATRIS. CareTrack can give you the machine information needed for better planning and smarter working; such as daily usage reports, location reports and service maintenance reminders using guided diagnostics to track and analyze machines remotely. You can save fuel. You can reduce costs. You can maximize profitability. You can with CareTrack. 9

10. Get attached. Get flexible on site with Volvo attachments. Choose from an extensive range of buckets, pallet forks and grapples, perfectly-matched to the machine’s link-arm geometry and breakout force. Volvo’s attachment brackets let you quickly interchange between options so you can ‘attach and go’. Standard Volvo Attachment Bracket Volvo’s standard hydraulic attachment bracket, is internationally ISO standardized and allows a quick and safe interchange of attachments for more flexibility on site. The strong, open bracket design enables the operator to clearly see attachment points from the cab. 10

12. VOLVO L45G, L50G IN DETAIL. Engine Instrumentation: All important information is centrally located in the operator’s field of vision. Display for Contronic monitoring system. Heater and defroster: Heater coil with filtered fresh air and fan with auto and 11 speeds. Defroster vents for all window areas. Operator’s seat: Operator’s seat with adjustable suspension and retractable seat belt. The seat is mounted on a bracket on the rear cab wall and floor. The forces from the retractable seat belt are absorbed by the seat rails. Standard: The cab is tested and approved according to ROPS (ISO 3471, SAE J1040), FOPS (ISO 3449). The cab meets with requirements according to ISO 6055 (Operator overhead protection - Industrial trucks) and SAE J386 (“Operator Restraint System”). Engine: Volvo’s V-ACT Tier 4i / Stage III B approved, 4 liter, 4-cylinder in-line four stroke diesel engine, turbocharger with waste gate, Common Rail fuel injection, cooled external Exhaust Gas Recirculation (EGR), diesel particulate filter (DPF). The throttle application is transmitted electrically from the throttle pedal or the optional hand throttle. Air cleaning: Three-stage Cyclone precleaner - primary filter - secondary filter. Cooling system: Air-to-air cooling pack. Powerful hydraulic fan electronically controlled. L45G Volvo D4H 30 (1,800) 75 (101) 73 (98) 24.2 (1,450) 425 (313) 406 (299) 1,200 - 1,800 4 (244) L50G Volvo D4H 31.7 (1,900) 87 (117) 85 (114) 24.2 (1,450) 490 (361) 468 (345) 1,200 - 1,800 4 (244) Engine Max power at SAE J1995 gross ISO 9249, SAE J1349 net Max torque at SAE J1995 gross ISO 9249, SAE J1349 net Economic working range Displacement L45G, L50G r/s (r/min) kW (hp) kW (hp) r/s (r/min) Nm (lbf) Nm (lbf) Use emergency hammer to break window Emergency exit: Sound level in cab according to ISO 6396: External sound level according to ISO 6395: LpA dB(A) 68 LwA dB(A) 102 r/min l (in3) L45G Power hp 120 Torque Nm kW Economic working range lbf ft 90 600 443 Engine Max power at SAE J1995 gross ISO 9249, SAE J1349 net Max torque at SAE J1995 gross ISO 9249, SAE J1349 net Economic working range Displacement Hydraulic system System supply: One load-sensing axial piston pump with variable displacement. The steering function always has priority. Valves: Double-acting 3-spool valve (4-spool valve optional). The main valve is controlled by an appropriate pilot valve. Lift function: The valve has four positions: Lift, hold (neutral), lower and float position. Optional inductive/magnetic automatic boom kick-out can be switched on and off and is adjustable to any position between maximum reach and full lifting height. Tilt function: The valve has three positions: Rollback, hold (neutral) and dump. Inductive/magnetic automatic tilt can be adjusted to the desired bucket angle (bucket positioner). Cylinders: Double-acting cylinders for all functions. Filter: Full-flow filtration through 10 micron (absolute) filter cartridge in a combined suction-return-filter. Integrated valve for thermostatically controlled oil circuit through the oil-cooler. r/s (r/min) kW (hp) kW (hp) r/s (r/min) Nm (lbf) Nm (lbf) 80 550 406 100 500 70 369 450 60 332 80 50 400 295 60 40 350 258 r/min l (in3) 300 30 221 40 20 250 185 20 10 200 148 Power Torque 150 0 110 0 r/min 800 1000 1200 1400 1600 1800 2000 r/s 15 20 25 30 35 L50G Power hp 120 Torque Nm kW Economic working range lbf ft 600 90 443 80 550 406 100 70 500 369 60 450 332 80 L45G, L50G 26 (260) 132 (34.9) 36.7 (2,200) 2,5 (25) L45G 5,3 1,1 3,2 9,6 50 400 295 Working pressure max Flow at Engine speed Pilot working pressure Cycle times Mpa (bar) l (US gal)/min r/s (r/min) Mpa (bar) 60 350 40 258 300 30 221 40 L50G 6,4 1,6 3,9 11,9 20 250 185 Raise Tilt s s s s 20 10 200 148 Power Torque Lower, empty Total cycle time 0 150 110 0 r/min 800 1000 1200 1400 1600 1800 2000 r/s 15 20 25 30 35 12

13. Service Filling capacities: Fuel tank Engine oil Engine coolant Hydraulic tank Transmission oil Front axle oil Rear axle oil Drivetrain Electrical system Contronic electrical system with central warning light and buzzer, providing clear and easy to read information to the operator. LCD display with main and sub information field, adjustable to various languages. Display information in three categories: Information on continuous operating data, Check requests (based on vehicle and error messages) and Warning (with alarm texts). Additional audible warning by a buzzer. Indicator and activation lights for various control and monitoring functions. Gauges for Fuel tank level, hydraulic oil temperature and engine temperature. Keypad also provides display navigation on the central instrument. Direct access buttons for Engine, Transmission, Hydraulics, Axles & Brakes, Electric, Machine, Vehicle messages, Service and Setup. Antitheft equipment optional. l (US gal) l (US gal) l (US gal) l (US gal) l (US gal) l (US gal) l (US gal) 150 (39.6) 14 (3.7) 20 (5.3) 95 (25) 2,2 (0.58) 17,0 (4.5) 18,3 (4.8) Transmission The hydrostatic transmission is an infinitely variable transmission. The speed gears limit the max. travel speed within the range - without any tractive power interruption. Maximum rimpull is available in all gears, regardless of the driving direction. Automatic regulation ensures easy operation. Load limiting control protects the engine when additional power is requested by working hydraulics and auxiliary power take-off. No overheating in overload conditions. Axles: Volvo fully floating axle shafts with hub planetary reductions and cast steel axle housing. Fixed front axle and oscillating rear axle, self-lubricated. 100% differential lock on both axles. L45G, L50G Voltage Batteries Battery capacity Cold cranking capacity, approximate Alternator rating Starter motor output Brake system V V 24 2x12 2x100 830 3 080/110 5,5 (7.4) Ah A W/A kW (hp) Drivetrain L45G, L50G Travel speeds (Forward / Reverse) Service brake: Reliable wet disc brakes with nitrogen-charged accumulators. Dual circuit on front and rear axle Secondary brake: Dual circuit and hydrostatic retardation Inching-brake pedal: Hydraulic inching brake pedal provides hydrostatic braking for precise control of travel speed and service brake application. 1st stage: Wearless hydrostatic braking (inching) 2nd stage: Service brake application Parking brake: Dry disc brake on input shaft of front axle. Standard: The brake system complies with the requirements of ISO 3450 1st gear km/h (mph) 2nd gear km/h (mph) 3rd gear km/h (mph) 0 - 5 (0 - 3.1) 0 - 17 (0 - 10.5) 0 - 40 (0 - 25) ±12 360 (14.2) 1 730 (68.1) Angle of rear axle oscillation Oscillation at wheel at Track width Steering ° mm (in) mm (in) Steering system: Load sensing hydrostatic articulated steering. System supply: The steering system has priority feed from the load-sensing axial piston pump with variable displacement. Steering cylinders: Two double-acting cylinders. Elastical end-stops. L45G Number of brake discs per wheel front/rear Accumulators Accumulators for parking brake L50G Number of brake discs per wheel front/rear 1/1 L45G, L50G Steering cylinders Working pressure l (US gal) l (US gal) 3x0,5 (3x0.13) 1x0,5 (1x0.13) 2 Mpa (bar) 17,5 (175) l min 70 front 1 Maximum flow (US gal) min (18.5) l 2x0,5, 1x1,0 (2x0.13, 1x0.26) 1x1,0 (1x0.26) Accumulators Max articulation Linkage Linkage system Lift cylinders Tilt cylinders Lift time (loaded) Lowering time (empty) Dump time ° ±40 (US gal) l (US gal) L45G L50G Accumulators for parking brake TP 2 1 s s s 5,3 3,2 1,1 6,4 3,9 1,6 13

14. SPECIFICATIONS L45G. L45G With TP-linkage, TPV attachment bracket and 17.5 R25 tires 5 280 (17' 4'') 2 650 (8' 8'') 435 (1' 5'') 2 990 (9' 9'') 1 040 (3' 4'') 3 470 (11' 4'') 3 725 (12' 2'') 55 45 45 75 255 (10'') 1 730 (5' 8'') 2 190 (7' 2'') 3 485 (11' 5'') 4 760 (15' 7'') 2 540 (8' 4'') 40 B C D F G J K O P R S U X Y Z a2 a3 a4 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) ° ° ° ° mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) ° TPV Attachment bracket Long Boom With Loading Fork TPV attachment bracket Center of gravity 500 mm (1' 8'') A B C D E F Tipping load full turn (ISO 1 4397) Working load according to EN 474-3, 60/80 % Working load 80%, transport position, 40° and full turn mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb) kg (lb) kg (lb) 785 (2' 7'') 1 475 (4' 10'') 650 (2' 2'') 1 705 (5' 7'') 3 490 (11' 5'') 4 225 (13' 10'') 4 420 (9,744) 2 650 / 3 530 (5,842 / 7,782) 4 000 (8,818) 1 135 (3' 9'') 1 745 (5' 9'') 825 (2' 9'') 1 705 (5' 7'') 3 695 (12' 2'') 4 430 (14' 6'') -560 (-1,234) -340 /- 450 (-749 / -992) – 14

15. L45G With TP-Linkage, TPV attachment bracket (welded version) and 17.5 R25 tires LONG BOOM GENERAL PURPOSE LIGHT MATERIAL 4-in-1 High-Tip Capacity heaped m3(yd3) kg/m3 (lb/yd3) 1,4 (1.8) 1 800 (3,030) 1,5 (2.0) 1 700 (2,697) 1,8 (2.4) 1 400 2 (2.6) 1 200 1,2 (1.6) 1 900 (3,203) 2 (2.6) 1 000 (1,854) - Material density - Leichtgutschaufel (2,360) Leichtgutschaufel (2,191) Static tipping load, straight (ISO 14397) Static tipping load, full turn 40° (ISO 14397) Hydraulic lifting capacity, max. Breakout force A Total length L Lift height, max. V Bucket width kg 5 970 (13,160) 5 930 (13,073) 5 780 (12,742) 5 670 (12,500) 5 650 (12,456) 4 950 (10,912) - (lb) kg 5 290 (11,622) 70 (15,736) 62 (13,938) 5 250 (11,547) 69,4 (15,511) 59,7 (13,421) 5 120 (11,287) 67,5 (15,174) 53 (11,914) 6 505 (21' 4'') 4 810 (15' 9'') 2 250 (7' 5'') 10 390 (34' 1'') 85 (3'') 2 690 (8' 10'') 1 025 (3' 4'') 1 850 (6' 1'') 8 660 (19,092) 5 020 (11,067) 66 (14,837) 48 (10,790) 6 615 (21' 8'') 4 940 (16' 2'') 2 250 (7' 5'') 10 460 (34' 4'') 85 (3'') 2 610 (8' 7'') 1 100 (3' 7'') 1 925 (6' 4'') 8 690 (19,158) 5 000 (11,023) 66,5 (14,949) 66 (14,837) 6 295 (20' 8'') 4 815 (15' 10'') 2 250 (7' 5'') 10 305 (33' 10'') 120 (5'') 2 790 (9' 2'') 815 (2' 8'') 1 640 (5' 5'') 8 850 (19,511) 4 370 (9,634) 57,5 (12,926) - 6 955 (22' 10'') 5 695 (18' 8'') 2 250 (7' 5'') -640 (-1,410) - - 200 (8'') - - (lb) kN (lbf) kN (lbf) mm (ft/in) 6 350 (20' 10'') 6 385 (20' 11'') mm (ft/in) 4 740 (15' 7'') mm (ft/in) 2 250 (7' 5'') mm (ft/in) (33' 10'') mm (ft/in) 85 (3'') mm (ft/in) 2 800 (9' 2'') mm (ft/in) 930 (3' 1'') mm (ft/in) 1 750 (5' 9'') kg (lb) (19,026) 4 790 (15' 9'') 2 250 (7' 5'') 10 320 (33' 10'') 85 (3'') 2 780 (9' 1'') 945 (3' 1'') 1 770 (5' 10'') 8 650 (19,070) 10 300 a1 Clearance circle 10 675 (35') - T Digging depth H Dump height, 45° M Reach at max. height N Reach, max. 95 (4'') - - 4 230 (13' 11'') 1 490 (4' 11) 2 670 (8' 9'') 9 090 (20,040) 170 (7'') 270 (10'') 8 630 Operating weight - 15

16. SPECIFICATIONS L50G. L50G With TP-linkage, TPV attachment bracket and 17.5 R25 tires 5 380 (17' 8'') 2 650 (8' 8'') 435 (1' 5'') 2 980 (9' 9'') 1 000 (3' 3'') 3 525 (11' 7'') 3 780 (12' 5'') 54 45 44 76 255 (10'') 1 730 (5' 8'') 2 190 (7' 2'') 3 535 (18' 2'') 4 760 (15' 7'') 2 540 (8' 4'') 40 B C D F G J K O P R S U X Y Z a2 a3 a4 mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) ° ° ° ° mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) ° TPV Attachment bracket Long Boom With Loading Fork TPV attachment bracket Center of gravity 500 mm (1' 8'') A B C D E F Tipping load full turn (ISO 14397) Working load according to EN 474-3, 60/80 % Working load 80%, transport position, 40° and full turn mm (in) mm (in) mm (in) mm (in) mm (in) mm (in) kg (lb) kg (lb) kg (lb) 800 (2' 8'') 1 505 (4' 11'') 655 (2' 2'') 1 745 (5' 9'') 3 585 (11' 9') 4 320 (14' 2'') 4 810 (10,604) 2 880 / 3 840 (6,349 / 8,466) 4 000 (8,818) 1 060 (3' 6'') 1 705 (5' 7'') 785 (2' 7'') 1 745 (5' 9'') 3 735 (12' 3'') 4 470 (14' 8'') -420 (-926) -240 / 120 (- 530 / - 265) - 16

17. L50G With TP-linkage, TPV attachment bracket (cast version) and 17.5 R25 tires LONG BOOM GENERAL PURPOSE LIGHT MATERIAL 4-in-1 High-Tip Capacity heaped m3(yd3) kg/m3 (lb/yd3) 1,5 (2.0) 1 900 (3,203) 1,6 (2.1) 1 700 (2,865) 1,8 (2.4) 1 500 2 (2.6) 1 300 1,4 (1.8) 1 900 (3,203) 2,3 (3.0) 1 000 (1,686) - Material density - Leichtgutschaufel (2,528) Leichtgutschaufel (2,191) Static tipping load, straight (ISO 14397) Static tipping load, full turn 40° (ISO 14397) Hydraulic lifting capacity, max. Breakout force A Total length L Lift height, max. V Bucket width a1 Clearance circle T Digging depth H Dump height, 45° M Reach at max. height N Reach, max. kg 6 560 (14,462) 6 510 (14,352) 6 400 (14,110) 6 290 (13,867) 6 080 (13,404) 5 550 (12,236) - (lb) kg 5 810 (12,809) 86,5 (19,446) 72 (16,186) 5 750 (12,677) 86 (19,334) 69 (15,512) 6 495 (21' 4'') 4 900 (16' 1'') 2 250 (7' 5'') 10 385 (34' 1'') 10 435 (34' 3'') 10 505 (34' 6'') 10 475 (34' 4'') 10 740 (35' 3'') 95 (4'') 95 (4'') 95 (4'') 2 845 (9' 4'') 2 775 (9' 1'') 2 695 (8' 10'') 1 000 (3' 3'') 1 040 (3' 5'') 1 115 (3' 8'') 1 830 (6') 1 890 (6' 2'') 1 970 (6' 6'') 9 430 (20,790) (20,767) (20,834) 5 670 (12,500) 84,5 (18,996) 64 (14,388) 6 580 (21' 7'') 4 980 (16' 4'') 2 250 (7' 5'') 5 570 (12,280) 83 (18,659) 58 (13,039) 6 690 (21' 11'') 5 235 (17' 2'') 2 250 (7' 5'') 5 390 (11,883) 81,5 (18,322) 65 (14,613) 6 560 (21' 6'') 4 905 (16' 1'') 2 250 (7' 5'') 4 910 (10,825) 73 (16,411) - 7 030 (23' 1'') 5 915 (19' 5'') 2 250 (7' 5'') -510 (-1,124) - - 150 (6'') - - - - - 130 (5'') 200 (8'') (lb) kN (lbf) kN (lbf) mm (ft/in) 6 460 (21' 2'') mm (ft/in) 4 880 (16' 0'') mm (ft/in) 2 250 (7' 5'') mm (ft/in) 10 360 (34') mm (ft/in) mm (ft/in) 2 865 (9' 5'') mm (ft/in) mm (ft/in) 1 810 (5' 11'') kg (lb) 95 (4'') 130 (5'') 2 745 (9') 965 (3' 2'') 1 810 (5' 11'') 9 670 (21,319) 105 (4'') 4 330 (14' 2'') 1 505 (4' 11'') 2 710 (8' 11'') 9 890 (21,804) 965 (3' 2'') 9 410 (20,745) 9 420 9 450 Operating weight - 17

18. equipment. STANDARD EQUIPMENT L45G L50G L45G L50G Engine Diesel engine, direct fuel injection Extra fuel filter Cold start aid Dry-type air filter Preparation for pre-cleaner Filtration screens on air inlets Reversible cooling fan Electrical system Alternator 55 A Lighting Main head lights (halogen) upper/dipped/asymmetrical Working lights (2 front/2 rear) Parking lights Rear lights Brake lights Direction indicators Hazard warning lights Reversing lights Cab lighting Instrumentation & controls Multi-function joystick 24 Volt accessories socket Forward horn Hazard warning switch Safety start Electronic Information System Analog information for: Fuel level Engine temperature Drive system oil temperature LED-illuminated symbols (color-coded) for: Direction (forward/reverse) Indicators (left/right) Pre-heater (option) Main beam head lamp Differential locks Boom suspension system (option) Loading fork operation (option) LED-illuminated symbols (red) with acoustic signal for: Parking brake Air filter restriction Drive system oil temperature Engine temperature Engine oil pressure Battery charging Return filter Touch pad with symbols and integrated LEDs for: Parking lights Working lights (front/rear) Windscreen wiper (rear) Rotating beacon (option) Boom suspension system on/off (option) Locking and activation of Volvo-attachment bracket Activation of multi-function joystick for directional change Digital LED display activated by dual function keys for: Entry and retrieval of operating information Optional anti-theft function control Drivetrain Hydrostatic drive Operator-selected 100% differential locks in both axles Tires 17.5 R25 Hydraulic system Load-Sensing Hydraulics Axial piston pump Control valve three-spool system 3rd hydraulic circuit and couplings Cab, Exterior ROPS/FOPS-cab with flexible mountings Lockable door All-round tinted safety glass Windscreen wiper (front/rear) Windscreen washer (front/rear) Door stops External rear view mirrors (right/left) Cab filtration system Cab, Interior 4-way adjustable operator’s seat Left armrest Cab, Interior Air conditioner Heater with air-filter and defroster (front/rear) Adjustable steering column Left armrest Cab, Interior Seat belt Sun visor Cab filtration Hook for coat Cup holder Emergency hammer Storage box in the cab Rear view mirrors (left/right) Working Equipment Automatic bucket leveller Hydraulic quick-change attachment bracket Carriage Body Fenders (front/rear) Fender extensions (optional) Lockable engine hood Lockable fuel-tank cap Vertical exhaust Towing device Lifting eyes International Standards for Machines and Production Quality: DIN/ISO 9001 Safety: CE - Criteron Machine guide-lines 2006/42/EC ROPS ISO 3471 FOPS ISO 3449 Operating weight ISO 7131 Tipping load / Payload: ISO 14397-1 EMC (Electromagnetic Compatibility) 89/336/EEC plus supplement Environment: DIN/ISO 14001 Sound regulation: 2000/14/EC • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • OPTIONAL EQUIPMENT (Standard on certain markets) L45G L50G Service Wheel chock Tool Kit Central Lub. unit (Volvo) Engine Hand inch valve Hand throttle Turbo II Prefilter Air pre-cleaner, oil-bath type Tropical cooling Fuel pre-heater Electrical Rotating beacon foldable Prep. rotating beacon magnetic Rev. alarm audible switchable Reverse alarm audible Rev. alarm audio vis. switchable Anti theft device Rear lights protection Headlights protection Working lights guards, front/rear Xenon work lights, front/rear Care Track GSM Care Track Satellite Transport lights El. headlights 350 mm (1' 2") Road light equipment width 2.5 m (8' 2") Power outlet 12 V Rotating beacon magnet Cab Door all glass Foldable r.h. window Split door Seat fab. air/susp. heat Seat mec./susp. Radio preparation 12 V Radio Heated rearview mirrors Rearview mirrors inside cab • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 18

19. OPTIONAL EQUIPMENT (Standard on certain markets) SELECTION OF VOLVO OPTIONAL EQUIPMENT L45G L50G Cab 1 lever ctrl. incl. 3rd hyd. function 3 lever ctrl. 4 lever ctrl. incl. 4th hyd. function Seat belt 3" Comfort drive control (CDC) Hydraulics Hyd. oil mineral VG46 HV Hydr. Couplings Boom suspension system Tilt speed limiter mechanical Boom kickout 4th function Tilt control Hyd. oil BIOsynth VG46 HLP PA Hyd. oil mineral VG68 HV Safety valve for tilt cylind. Hyd. oil mineral VG32 HV Extra oil ret. line via filter Other Color Level 1 (yellow parts) Preparation for licence plate Side marking reflectors SMV warning triangle Trailer socket Belly guards, front/rear Windshield guard, rear Windshield guard, front Protect. wax coating incl. cyl. Engine hood protection Color Level 1+2 Auto Engine Shutdown L45/50G GY TL-3A+ 17.5 R25 Removable rear left fender Tires Front Mud flaps MI 17.5R25 XHA MI 15.5R25 XHA GY 15.5-25 SGL Mudguard extension 75 mm Extended mud flaps GY 17.5-25 SGL GY 17.5R25 RT-3B NO 540/65R24 TRI2 BR 17.5R25 VSW B2,25 MI 15.5R25 XMINE-D2 Wheels for transport only MI 500/70 R24 XMCL NO 440/80R24 TRI 2 MI 17.5R25 XMINE-D2 TR 600/55-26.5 T421 MI 17.5R25 XHA B2,4 BR 15.5R25 VUT MI 15.5R25 XHA B2,4 GY 17.5R25 RT-3B B2,4 GY 550/65R25 GP-3D MI 17.5R25 XHA SPW High flow 125 l/min Long boom ATTACHMENTS • • • • • • • • • • Boom Suspension System • • • • • • • • • • • • • • • • • • • • • Comfort Drive Control (CDC) • • • • • • • • • • • • • • • • • • • • • • • • • • • • Hydraulic 3rd and 4th function • • • • • • • • • • • • • • • • • • • • • • • • • • Tilting condenser • • • • • • • • • • • • • L45G L50G Buckets Straight with teeth and bolt on edges High tipping Light material Multi purpose Grading Clamp Other attachments Log grapples Forks Material handling arm • • • • • • • • • • Automatic Lubrication System • • • • • • 19

20. volvo construction equipment Volvo Construction Equipment is different. Our machines are designed, built and supported in a different way. That difference comes from an engineering heritage of over 175 years. A heritage of thinking first about the people who actually use the machines. About how to help them be safer, more comfortable, more productive. About the environment we all share. The result of that thinking is a growing range of machines and a global support network dedicated to helping you do more. People around the world are proud to use Volvo. And we’re proud of what makes Volvo different. Not all products are available in all markets. Under our policy of continuous improvement, we reserve the right to change specifications and design without prior notice. The illustrations do not necessarily show the standard version of the machine. Volvo Construction Equipment Ref. No. VOE2210009251 Printed in USA 03/12 – 0,0 Volvo, Asheville Copyright © 2012 Volvo English USA www.volvoce.com/na Volvo L45G service repair manual Download

21. Accumulator removed, checking charging pressure Op nbr 527-001 Total procedure time (hr): 0.20 Tools: 88830175 Pump 11666051 Pressure gauge 14290266 Hose E-2000 1. Connect E-2000 to pressure accumulator. Connect the other tools as shown. Figure 1 Check removed pressure accumulator 1. 2. 3. 4. 5. Pump 11666041 Accumulators E-2000 Pressure gauge 11666051 Hose 14290266 2. Pump oil into the pressure accumulator. After a few pump strokes, the pressure rises to precharge pressure. Read display on pressure gauge. For set value, see Brakes, specifications. NOTE! If the precharge pressure does not reach the set value, change the pressure accumulator. 3. Discard faulty pressure accumulator, see Accumulator, discarding.

22. the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading

23. Accumulator, check Op nbr 527-009 Total procedure time (hr): 0.40 1. Place the machine in service position. Removal 2. Switch on the engine and depressurise the brake system by depressing the brake pedal repeatedly. 3. Remove hydraulic hose (1). Figure 1 4. Loosen clamp (2) and remove pressure accumulator. Checking 5. Carry out pressure test on pressure accumulator, see Accumulator removed, checking charging pressure. Installing 6. Install pressure accumulator. Tighten clamp (2) and fit hydraulic hose (1). 7. Carry out a function test.

24. Accumulator, discarding Op nbr 900-050 WARNING A discarded accumulator which is not punctured may still contain high pressure and must always be handled with great care. WARNING Use safety glasses. 1. Accumulators that are to be discarded must not constitute a hazard. This is done by carefully puncturing the accumulator with a Ø3 mm (0.118 in) drill. Figure 1 Accumulator A. Drill here with a Ø3 mm (0.118 in) drill 1. 2. 3. Nitrogen gas space Rubber diaphragm Connection for oil

25. ACM (After treatment control module), replacing, non-programmed Op nbr 254-022 Total procedure time (hr): 0.90 Tools: Tech Tool Service Tool 88890180 Interface 88890027 Cable 1. Place the machine in service position. 2. Connect VCADS Pro and perform the operation 25801-3 MID 233 control unit, Programming. 3. Switch off the battery connection switch. 4. Unscrew clamp (1) and remove electric plug connector (2) from control unit. Figure 1 ACM, control unit exhaust after-treatment 5. Unscrew fixing bolts (4 pcs.) and remove control unit (3). 6. Fit new control unit and tighten bolts. 7. Connect electric plug connector to control unit and tighten clamp. 8. Switch on the battery disconnect switch. 9. Complete VCADS Pro-Operation 25801-3 MID 233 Control unit, Programming. 10. Perform a service regeneration to secure the actual soot level in the DPF, see Perform a service regeneration. 11. Perform a trial run and ensure that there are no error codes.

26. ACM (After treatment control module), replacing, pre-programmed Op nbr 254-023 Total procedure time (hr): 0.80 Tools: Tech Tool Service Tool 88890180 Interface 88890027 Cable 1. Place the machine in service position. 2. Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'. Use the function: Save all read parameters to job card.  3. Switch off the battery connection switch. 4. Unscrew clamp (1) and remove electric plug connector (2) from control unit. Figure 1 ACM, control unit exhaust after-treatment 5. Unscrew fixing bolts (4 pcs.) and remove control unit (3). 6. Fit new control unit and tighten bolts. 7. Connect electric plug connector to control unit and tighten clamp. 8. Switch on the battery disconnect switch. 9. Connect VCADS Pro computer to the machine, and perform the operation '17030-3 Parameter, programming'. Program previously read parameters according to work order.  10. Perform a service regeneration to secure the actual soot level in the DPF, see Perform a service regeneration. 11. Perform a trial run and ensure that there are no error codes.

27. Air cleaner primary filter, change Op nbr Total procedure time (hr): NaN This is part of another procedure NOTE! During each servicing, check the air lines (filter and engine) for leaks. Replace defective parts and tighten any loose hose clamps. 1. Upon request, drain the dust valve (1) by pressing the discharge vent together. Figure 1 Air cleaner 1. 2. Dust valve Lock tongue, filter cover lock 2. Pull the yellow lock tongue (2) to release the cover lock. Turn the filter cover anti-clockwise and remove. 3. Remove the primary filter (3) from the filter housing. Figure 2 Primary filter The primary filter can be cleaned no more than five times. After that, the filter must be replaced. The filter must also be replaced if it is damaged or if after cleaning the message "Check clogged engine air filter" appears on the information display. Cleaning 4. Insert the cleaned or new primary filter. 5. Clean and close the filter cover. NOTE! If the message "Check clogged engine air filter" appears in the information display after primary filter servicing, the secondary filter must also be replaced.

28. Air cleaner secondary filter, change Op nbr Total procedure time (hr): NaN This is part of another procedure NOTE! The secondary filter should be replaced every third primary filter replacement and at least every other year. 1. First remove the primary filter, see Air cleaner primary filter, change. 2. Remove the secondary filter (4) from the filter housing. Figure 1 Secondary filter 3. Insert the new secondary filter. 4. Insert the primary filter and close the filter cover; see Air cleaner primary filter, change.

29. Air conditioning, capacity Air conditioning system Fill quantity for new fill (refrigerant R134a) 1,85 kg (4.1 lb)

30. Attachment bracket cylinder, reconditioning Op nbr 924-034 1161370 Glue 8714377 Cleaning spray Applies only to machines with vision-optimised attachment bracket. Figure 1 Vision-optimised attachment bracket Figure 2 Locking cylinder 1. 2. 3. 4. 5. Circlip Lock ring Guide Piston rod Piston 1. Remove circlip (1). 2. Push in guide (3), past lock ring (2). 3. Remove the lock ring. 4. Pull out piston rod (4). 5. Remove piston (5) from the piston rod. Clean the threads on the piston and the piston rod. Use cleaning spray 8714377. 6. Clean the cylinder. 7. Check all parts for wear and damage. 8. Apply glue 1161370 to the piston rod threads. 9. Install piston (5) on the piston rod. Tightening torque: 60 N m (6 kgf m) (44 lbf ft) The glue has to harden for four hours. NOTE!

31. The cylinder must not be filled with oil during the hardening period. 10. Oil the cylinder and piston seal. 11. Push the piston rod into the cylinder. 12. Push in guide (3) past the lock ring groove. 13. Install the lock ring. 14. Pull the guide out against the lock ring. 15. Install the circlip.

32. Attachment locking hydraulic cylinder (vision-optimised bracket), replacing Op nbr 924-035 Total procedure time (hr): 0.60 Axle stand, 1000 kg (2205 lb) Applies only to machines with vision-optimised attachment bracket. Figure 1 Vision-optimised attachment bracket 1. Start the engine and secure the lifting arms with the axle stand. Tilt the attachment bracket outwards. Figure 2 2. Unlock the attachment lock (pull the studs into the attachment bracket) using the locking button. Turn off the engine and take out the ignition key. 3. Remove the cover plate. 4. Disconnect the hydraulic hoses from lead-through connections on the attachment bracket. Plug the lead-through connections.

33. Figure 3 1. Hydraulic hoses 5. Remove the bolt retaining the hydraulic cylinder. 6. Press in the pins and push the cylinder over to one side. 7. Remove the lock ring from the pin and tap out the pin. Remove the hydraulic cylinder together with the hoses. 8. Transfer required parts to the new cylinder. 9. Install the new cylinder and install the lock pin and the lock ring. Install the bolt retaining the cylinder. 10. Connect the hoses to the lead-through couplings. 11. Start the engine and test the function of the attachment locking and check that there are no leaks of hydraulic oil. 12. Re-install the cover.

34. Automatic engine shut-down This function shuts down the engine automatically to save fuel when the machine is not under working conditions for a longer time. The driver is warned of the pending engine shutdown and has the opportunity to prevent it. Function description The engine shut down sequence will be started in real time while the machine is in the automatic engine shutdown conditions. Figure 1 Time sequence A. B. C. D. Automatic engine shutdown conditions Information message on display unit Signal tone The engine is turned off Automatic engine shutdown conditions (A) Option parameter (FAU) is activated. Operating parameter automatic engine shutdown "ON" Machine stopped and parking brake activated. Let engine idle at lower idle speed (< 1000 rpm / 16.6 rps) DPF regeneration is not in progress. Information message “Automatic engine shutdown” on I-ECU has not disappeared when ESC button pressed on keypad.       Information message, display (B) Figure 2 Information message, display One minute before engine shutdown, the information message appears on the I-ECU.  To abort the engine shut down sequence: - Press "ESC" button, or - Release the parking brake. Signal tone (C) Three seconds before engine shutdown, a signal tone will be generated 3 times.  The engine is turned off (D) For more information, see Software parameters, description.

35. Axle suspension, replacing bushes and seals Op nbr 755-003 Total procedure time (hr): 4.00 Tools: 11667001 Handle 11667110 Drift plate 6999068 Drift plate 9993722 Support 11666054 Jack 88830175 Pump 1. Remove rear axle, see Axle, removing. 2. Lower the axle onto a suitable surface. 3. Remove gearbox, see Transmission, removing and installing. 4. Remove shaft seal ring (1) on both sides of swivel roller bore. Figure 1 5. Attach tools and withdraw bush from swivel bearing bore. Figure 2 NOTE! Repeat the procedure on the other side. 6. Clean bush bearing seat.

36. WARNING Use thick gloves when shrinking sleeves and bushings with liquid nitrogen. Severe frostbite and cold injuries are sustained on exposed skin. See national regulations for handling liquid nitrogen. 7. Supercool both bearing bushes in liquid nitrogen for approx. 2 to 3 minutes, and insert flush into swivel bearing bore taking into account installation position. Figure 3 NOTE! Installation position for bearing bushes. Insert with lubricant groove in 6 o'clock position (arrow). 8. Coat contact face of swivel bearing bore/shaft seal ring with spirit, and coat with grease in the area of the seal and dust lip. Figure 4 9. Insert both shaft seal rings with drift plate 11667110 taking into account installation position (sealing lip points towards oil chamber). 10. Install gearbox, Transmission, removing and installing. 11. Install rear axle, see Axle, installing.

37. Axle, installing Op nbr 463-003 Total procedure time (hr): 1.75 WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 1. Suspend machine at the lifting eyes of the rear frame using a suitable lifting tool. 2. Bring rear axle into position below machine using stand jack. NOTE! Weight of rear axle with dropbox and hydrostatic motor approx. 562 kg (1239 lb) Figure 1 3. Lower machine onto supports. Figure 2 4. Raise rear axle using the stand jack and align to the receiver holes on the rear frame. 5. Mount pendulum pin. Pendulum pin weight approx. 13 kg (28.6 lbs)

38. Figure 3 NOTE! To avoid damage to the shaft seal ring when fitting the pendulum pin, pull in pendulum pin evenly with 2 bolts (M16 x 120), see diagram. 6. When the pendulum pin has reached its end position, measure distance from the journal to the machined surface of the crossmember. Select shims. NOTE! Allow an axial play of the pendulum pin of 0.2 - 0.7 mm (0.08 - 0.28 in). 7. Moisten shims with assembly paste and fit. Position bearing cover and tighten with a tightening torque of 220 Nm (162 lbf ft). Figure 4 1. 2. 3. 4. 5. Pendulum pin Shim washer Bearing cap washer screw NOTE! The spacers are fitted in the order of their thickness, starting with the thinnest. 8. Lower stand jack and remove mounting jig. 9. Check that the rear axle can move easily in the radial direction. If not, the axial play is too low. 10. Install high pressure hose (1) and leak-oil line (2) to hydrostatic motor

39. Figure 5 11. Remove the vacuum pump; see Vacuum pump, connection Figure 6 Disconnect the vacuum pump 12. Fit hydraulic line (1) for differential lock Figure 7 13. Fit hydraulic line (2) for service brake on the right and left axle bridges. 14. Connect electric pin plug connections (1) and (2) to solenoid valve hydrostatic motor.

40. Figure 8 15. Mount universal shaft (1) on dropbox. Tightening torque 80 Nm (59 lbf ft). Figure 9 16. Connect the connector for the inductive sensor (2). 17. Suspend machine from the lifting eyes on the rear frame using a suitable lifting tool, raise and remove supports. 18. Fit both rear wheels. Tightening torque 580 ± 20 Nm (428 ± 15 lbf ft). 19. Install the counterweight, see Counterweight, fitting. 20. Bleed the brake system, see Brake system, bleeding air. 21. Carry out test drive and check brake function.

41. Axle, removing Op nbr 463-002 Total procedure time (hr): 1.75 1. Place the machine in service position. 2. Switch on the engine and depressurise the brake system by depressing the brake pedal repeatedly. 3. Block articulation joint using “Joint lock”. Figure 1 4. Switch off the battery connection switch. WARNING The work involves handling heavy components - failure to stay alert may result in severe crushing injuries. 5. Remove the counterweight. Refer to Counterweight, removing. 6. Suspend machine at the lifting eyes of the rear frame using a suitable lifting tool. 7. Remove both rear wheels. 8. Bring suitable supports into position below the rear frame and lower the machine. Figure 2 9. Remove universal shaft (1) at dropbox

42. Figure 3 10. Separate the connector for the inductive sensor (2). 11. Separate electric pin plug connections (1) and (2) from solenoid valve hydrostatic motor. Figure 4 12. Remove hydraulic line (1) for differential lock Figure 5 13. Remove hydraulic line (2) for service brake on the right and left axle bridges. 14. Connect vacuum pump, see Vacuum pump, connection.

43. Figure 6 Connect the vacuum pump 15. Remove high pressure hose (1) and leak-oil line (2) on hydrostatic motor NOTICE When a hose has been disconnected, plug both the hose and the connection immediately. The hoses should be marked for correct connection. Figure 7 16. Unscrew fixing bolt (1) for pendulum pin. Remove bearing cover with shims. Figure 8 17. Bring mounting jig into position below axle using a stand jack. Raise mounting jig to relieve load on pendulum pin.

44. Figure 9 18. Screw remover bolt (M20) into pendulum pin (1). Drive out pendulum pin with a slip hammer. NOTE! Pendulum pin, weight approx. 13 kg (28.6 lbs) Figure 10 19. Lower stand jack. Raise machine until the rear axle can be withdrawn freely below machine. NOTE! Weight of rear axle with dropbox and hydrostatic motor approx. 562 kg (1239 lb)

45. Axles, changing oil Op nbr Total procedure time (hr): NaN This is part of another procedure Oil change front axle Planetary carrier and differential share a common oil system. WARNING Work carefully when changing oil as hot oil can cause severe burns to unprotected skin. 1. Drain oil from the front axle into a suitable container. NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Figure 1 Front axle 1. 2. 3. Drain, fill and check screw plug, planetary carrier Axle drive housing drain plug Filler/inspection screw plug, axle drive housing NOTE! To prevent injury from possible pressure build-up in the planetary carrier's oil system, move drain and inspection screw plug (1) to the highest position, release it carefully and remove. Then set the drain opening to the lowest position and drain oil. 2. Fill both planetary carriers with oil to overflow. For oil grade, see Recommended lubricants 3. Screw in lock screws (1) and (2) and tighten to 30 Nm (22 lbf ft). 4. Fill with oil to overflow via the filler/check bore (3) of the axle drive housing. For volume, see Front axle, capacity Low/high- speed machine. 5. Screw in lock screw (3) and tighten to 30 Nm (22 lbf ft).

46. 6. Check oil level after a few minutes and top up if necessary. NOTE! Rear axle and differential share a separate oil system. Oil change rear axle with dropbox, low-speed machine 7. Drain oil from the dropbox and rear axle into a suitable container. NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Figure 2 Oil change rear axle with dropbox, low-speed machine 1. 2. 3. 4. 5. Drain, fill and check screw plug, planetary carrier Axle drive housing drain plug Filler/inspection screw plug, axle drive housing Drop box drain plug Drop box filler/inspection screw plug 8. Fill both planetary carriers with oil to overflow. For oil grade, see Recommended lubricants. 9. Screw in lock screws (1) (2) and (4) and tighten to 30 Nm (22 lbf ft). 10. Fill the dropbox with approx. 1 litre (0.3 US gal) via the filler/check bore (5). Then fill the axle drive housing with oil to overflow

47. via the filler/check bore (3). For volume, see Rear axle, capacity Low-speed machine. 11. Screw in lock screws (3) and (5) and tighten to 30 Nm (22 lbf ft). 12. Check oil level after a few minutes and top up if necessary. NOTE! Rear axle and differential have separate oil systems. Oil change rear axle with hydrostatic transmission, high-speed machine 13. Drain oil from the gearbox and rear axle into a suitable container. NOTICE Always handle oils and other environmentally hazardous fluids in an environmentally safe manner. Figure 3 Oil change rear axle with hydrostatic transmission, high-speed machine 1. 2. 3. 4. 5. Drain, fill and check screw plug, planetary carrier Axle drive housing drain plug Filler/inspection screw plug, axle drive housing Gearbox drain plug Gearbox fill/check screw plug

48. 14. Screw in lock screws (2) and (4) and tighten to 30 Nm (22 lbf ft). 15. Fill both planetary carriers with oil to overflow. Then fill the axle drive housing with oil to overflow via the filler/check bore (3). For oil grade see Recommended lubricants. For volume, see Rear axle, capacity High-speed machine. 16. Screw in lock screws (1) and (3) and tighten to 30 Nm (22 lbf ft). 17. Fill the gearbox with oil to overflow via the filler/check bore (5). For oil grade see Recommended lubricants. For volume, see Rear axle, capacity High-speed machine. 18. Screw in lock screw (5) and tighten to 30 Nm (22 lbf ft). 19. Check oil level after a few minutes and top up if necessary.

49. Axles, tightening torques Fixing nuts, front axle to frame Fixing bolts, rear axle pin Wheel nuts, front and rear axle Fixing nuts for propeller shaft on dropbox and front axle 740 Nm (545 lbf ft) 220 Nm (162 lbf ft) 580± 20 Nm (428±15 lbf ft) 80 Nm (59 lbf ft)

50. Battery disconnect switch, description The function of the battery isolator switch is to disconnect the the machine's electrical system from the battery voltage when the machine is not used or during maintenance and repair work. Figure 1 Battery isolator switch The battery isolator switch is located on the left below the cab door and is connected to the positive side of the batteries. NOTE! The battery isolator switch does not break the power supply to the radio.