This is a very practical manual

1. Service Information
Document Title: Function Group: Information Type: Date:
General description 200 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
General description
The loader is equipped with an engine type TD122KLE.
The engine is a straight, six-cylinder, four-stroke, direct-injection, turbocharged diesel engine with a water-cooled
intercooler.
The engine is of the low-emission version.
The engine type designation, part number and serial number are stamped into the left side of the cylinder block.
The engine is installed in a closed space to reduce the external sound level.
The coolant pump is a double pump for separate cooling of the engine and the intercooler.
The cooling fan with vane motor is positioned behind the radiator and is hydrostatically driven by a variable piston pump,
Pump 3, (P 3).
The fan speed is controlled by the vehicle ECU (V-ECU), which receives information about the temperature in the following
systems:




Coolant temperature
Transmission oil temperature
Hydraulic oil temperature
Temperature in the front and rear axles (only if the machine is equipped with axle oil cooler.)
The hydrostatically controlled cooling fan speed results in higher engine output and a low sound level, as the cooling fan
does not often work at maximum speed.
The cooling system is based on a concept where the cooling of the engine, transmission, hydraulics and axle oil cooling,
(optional equipment) is integrated.
The cooling of these systems depends on the cooling fan speed.

2. Service Information
Document Title: Function Group: Information Type: Date:
Idling speed, checking and
adjusting
236 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Idling speed, checking and adjusting
Op nbr 23601
The following applies when checking:
Temperature: Normal working temperature
Low idling speed: 750 50 rpm
High idling speed: 2200 50 rpm
Units using a lot of electricity and the air conditioning, if applicable, must be turned off.
1. Select information about the engine and speed on operator display unit.
Low idling speed, checking and adjusting
2. Check, with the engine turned off, that the governor lever fits up against adjusting screw 3, see figure. Start the
engine and read off the low idling speed on the display unit. Adjust with adjusting screw 3. Lock the adjusting
screw with the nut and check the speed.
Figure 1
Idling speed, checking and adjusting
1.
2.
3.
Stop screw, high idling speed
Governor control arm, accelerator control
Adjusting screw, low idling speed
High idling speed, checking
3. With the engine turned off, check that the governor lever is limited by stop screw 1, see figure, when the

3. accelerator pedal is trodden right down. Let up the accelerator pedal, start the engine and depress the accelerator
pedal fully, so that the governor lever fits up against adjusting screw 1. Read off the high idling speed on the
display unit.
Figure 2
Idling speed, checking and adjusting
1.
2.
3.
Stop screw, high idling speed
Governor control arm, accelerator control
Adjusting screw, low idling speed
4. Any adjustment of the high idling speed must only be carried out by a diesel workshop authorised by Bosch.

4. Service Information
Document Title: Function Group: Information Type: Date:
Stall speed, checking 236 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Stall speed, checking
Op nbr 23602
The following applies when checking:
Temperature: Normal working temperature
Stall speed 1780 ±50 rpm
High idling speed: 2200 ±50 rpm
Units using a lot of electricity and the air conditioning (if applicable) should be turned off.
1. Check the high idling speed of the engine on the display unit.
2. Set Mode Selector SW143 to the Manual position, apply the service and parking brakes. Engage 3rd gear forward.
3. Run the engine at maximum speed and read off the stall speed.
NOTE!
If the recorded speed is higher than the prescribed stall speed, this may be due to the torque converter, the
transmission because of, for example, too low pressures. If the speed is lower than the prescribed, this may be
caused by the torque converter or the engine, or their peripherals, being in a poor condition. A deviating stall
speed is not necessarily a fault in itself which requires to be corrected, but should be used as an aid during trouble-
shooting.

5. Service Information
Document Title: Function Group: Information Type: Date:
Injection angle (injection
timing), checking and
adjusting
236 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Injection angle (injection timing), checking and adjusting
Op nbr 23630
998 7057 Timing tool
999 3590 Gear
999 3625 Guide
999 3824 Bolt
The following applies when checking:
Injection angle (timing) 11° ±0.5° B.T.D.C.
Checking
1. Turn off the battery disconnect switch.
Open the right engine cover on the machine.
2. Remove the plug from the governor housing and install the timing tool sensor.
NOTE!
The governor housing contains oil.
3. Connect the timing tool ground cable to ground in a suitable place on the injection pump.
Figure 1
Injection angle (injection timing), checking (principle diagram)

6. 1.
2.
3.
Sensor
Ground cable
998 7057
4. Remove the cover from the flywheel housing and install the tools.
Rotate the flywheel in the direction of rotation of the engine until both light emitting diodes light up. The
graduation on the flywheel should now be visible.
Figure 2
Injection angle (injection timing), checking (principle diagram)
1.
2.
999 3625
999 3590
5. Rotate the flywheel against the direction of rotation of the engine approx. 1/4 of a turn.
Figure 3
Direction of rotation of engine and injection pump
6. Slowly rotate the flywheel in the direction of rotation of the engine until both light emitting diodes light up.
Read off the graduation on the flywheel by the pointer. If the correct number of degrees are shown on the flywheel,
remove the tools and reset the machine.
Adjust when necessary and carry out a new check.

7. Figure 4
Injection angle (injection timing), checking (principle diagram)
1. Graduation on flywheel
Adjusting
7. Rotate the flywheel against the direction of rotation of the engine approx. 1/4 of a turn.
8. Rotate the flywheel in the direction of rotation of the engine until the correct number of degrees for the engine
appear by the indicator point.
NOTE!
Set the flywheel to a number of degrees within the higher end of the tolerance range. Make the adjustment
carefully and do not turn the flywheel back against the direction of rotation in order to fine-adjust the flywheel
position. If the flywheel has been been turned too far, the adjustment must be done over again.
9. Remove the guard over the pump coupling.
10. Remove the security seal from the clamping bolt
Figure 5
Removing security seal
1. 999 3824
11. Turn the injection pump shaft until both light emitting diodes on the timing tool is light.
NOTE!
The timing tool is very sensitive in order allow an exact adjustment.

8. 12. Tighten down the clamping bolt.
Check the injection angle (timing).
13. Install the security seal on the clamping bolt.
14. Remove the plug from the governor housing and install the timing tool sensor.
15. Remove the tools from the flywheel housing and install the cover.
16. Install the guard over the pump coupling.

9. Service Information
Document Title: Function Group: Information Type: Date:
Cooling system, description 260 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Cooling system, description
Figure 1
Cooling system
The advantages of the system integrated cooling system is:





Higher engine output and lower sound level as the cooling fan rarely works at maximum speed.
Faster warming up of the transmission.
Faster warming up of the drive axles, and that the axle oil always circulates in the axles also when the machine is
stationary. (Applies if the machine is equipped with extra axle oil cooling).
Warming of the oil in the hydraulic oil tank, also during transport operation.
Improved heating of the cab because of a higher flow of warm water through the heating radiator in the cab even
at a low engine speed.

10. Service Information
Document Title: Function Group: Information Type: Date:
Pump 3 (P3) Cooling fan
pump / Brake pump Flow
and pressure control,
description
260 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Pump 3 (P3) Cooling fan pump / Brake pump Flow and pressure
control, description
Figure 1
Pump 3 (P3) Cooling fan pump / Brake pump, Flow and pressure control
1.
2.
3.
Control piston
Pressure compensator
Flow compensator

11. 4. Accumulator, introduced on L220D / 1324–, to dampen pulses in LS-line

12. Service Information
Document Title: Function Group: Information Type: Date:
Cooling fan motor,
description
263 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Cooling fan motor, description
The cooling fan is driven by a vane motor with fixed displacement.
On machines equipped with external axle oil cooling, there is a non-return valve installed in a block on the connections for
the vane motor. The purpose of the non-return valve is to avoid cavitation in the vane motor when the engine is stopped
and the cooling fan is still rotating.
Figure 1
Cooling fan motor, principle diagram
1. Non-return valve, (only on machine with external axle oil cooling)
Figure 2
Cooling fan motor

13. Figure 3
Non-return valve, sectional view

14. Service Information
Document Title: Function Group: Information Type: Date:
Cooling fan speed control,
description
263 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Cooling fan speed control, description
The following systems are involved in the control of the cooling fan speed:




Hydraulic oil temperature, SE906
Axle oil temperature, front and rear axles (if axle oil cooler is installed) SE410 and SE411
The coolant temperature, at the outlet from the radiator, SE210
Transmission oil temperature, SE406





The coolant temperature, at the outlet from the radiator is dominating. The other temperatures do not have any
affect until close to their respective alarm trigger temperatures.
The axle oil temperature (front and rear) is only taken into consideration if axle cooling equipment is installed (is set
up via the display unit).
As the diesel engine thermostat restricts the water flow to the transmission oil cooler when the coolant
temperature is too low, the transmission oil temperature is only taken into consideration if the thermostat has
begun to open.
The diesel engine thermostat controls the coolant temperature for the engine, and temperature of the engine
coolant does thus not affect the speed of the cooling fan.
Proportional valve MA202 which controls the cooling fan speed is positioned on the central valve, see Section 9,
description of central valve.
Temperature limits
At the lower temperature limit, the cooling fan speed should be approx. 400 rpm 100 rpm.
The maximum speed of the cooling fan at the upper temperature limit is adjustable to different levels via the display unit.
Between the limits the relationship between temperature and speed is linear, see the Specifications:
“Temperature limits for cooling fan speed”.
In case of a fault in any of the sensors, this will be indicated on the operator display unit.
In case of a fault in the sensor for coolant temperature SE210, or sensor SE211 for the fan speed, the cooling fan speed will
also increase to approx. 900 rpm in order to safeguard cooling.
Cooling fan maximum speed
Different speeds of the cooling fan can be selected on the display unit, see Specifications:
“Cooling fan maximum speed”.
Sound test
When testing the sound level, service personnel can via the display unit request that the fan is run at a constant speed. This
request remains in force until the computer system is switched off. The constant speed is the same as 80 % of the maximum
permissible speed at the current setting (see "Cooling fan maximum speed").

15. Service Information
Document Title: Function Group: Information Type: Date:
Pump 3 (P3) Cooling fan
pump / Brake pump Stand-
by pressure, checking and
adjusting
263 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Pump 3 (P3) Cooling fan pump / Brake pump Stand-by pressure,
checking and adjusting
Op nbr 26310
11 666 019 Pressure gauge 0–6 MPa (0–870 psi)
11 666 037 Hose
999 3721 Service display unit
The following applies when checking:
Stand-by pressure, high idling
(LS-line disconnected)
1.95–2.10 MPa (19.5–21.0 bar) (283–305 psi)
Stand-by pressure, high idling
(LS-line connected)
approx. 3.0 MPa (30 bar) (435 psi)
Cooling fan Speed approx. 400 rpm
NOTICE
Check and when necessary clean the radiator. A clogged radiator with a reduced air flow will result in inaccurate
values.
Checking
1. Connect the pressure gauge to the pressure outlet on the central valve.
Figure 1
Central valve
1. Pressure outlet
2. Connect the service display unit to the socket on the right side panel in the cab.

16. 3. To make sure that brake charging does not start when checking, the connector at MA502 should be disconnected.
NOTICE
If the machine has been warmed up, the connector for proportional valve MA202 should also be
disconnected to make sure that there is a correct stand-by pressure and that the cooling fan speed will be
approx. 400 rpm.
Figure 2
Central valve
1.
2.
MA202, proportional valve, cooling fan speed
MA502, brake charging
4. Start the engine and select the correct menu for cooling fan speed on the service display unit under the Engine
menu.
Figure 3
Display menu
5. Read off the stand-by pressure and the fan speed at high idling. If the fan speed is incorrect, the radiator should be
checked and when necessary cleaned.
6. In case of correct values, reconnect the connectors at MA502 and MA202. Remove pressure gauge and service
display unit.
7. Any adjustment of the stand-by pressure is carried out on the flow compensator.
Adjusting
8. The stand-by pressure is adjusted with spacers on the flow compensator.
9. After adjusting and checking, reconnect connectors at MA502 and MA202. Remove pressure gauge and service
display unit.

17. Figure 4
The position of the pumps
1.
2.
3.
4.
5.
6.
Pump 1
Pump 2
Pump 3
Regulator block, pump 3
Flow compensator
Pressure compensator
Figure 5
Regulator block, pump 3
5 Flow compensator
6 Pressure compensator

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19. Service Information
Document Title: Function Group: Information Type: Date:
Pump 3 (P3) Cooling fan
pump / Brake pump
Cooling fan maximum
speed, checking
263 Service Information 2014/4/16
Profile:
WLO, L220D [GB]
Pump 3 (P3) Cooling fan pump / Brake pump Cooling fan maximum
speed, checking
Op nbr 26304
999 3721 Service display unit
The following applies when checking:
Speed when testing pressure 1400–1600 rpm
Normal maximum speed with a warm machine Varies between approx. 700 and 1200 rpm depending on need of
cooling
NOTE!
In cases where the correct speed of the cooling fan is achieved, there is no need for a new pressure check to be carried out.
NOTICE
Check and when necessary clean the radiator. A clogged radiator with a reduced air flow will result in inaccurate
values.
Checking
1. Connect the service display unit to the socket on the right instrument panel.
2. Start the engine and select the correct menu for cooling fan speed on the service display unit under the Engine
menu.
3. Press the * key and then give full throttle: Read off the cooling fan speed. If the fan speed is incorrect, the radiator
should be checked and when necessary cleaned.
4. If the speed is between 1400 and 1600 rpm, Pump 3 (P3) is correctly adjusted.
Figure 1
Display menu
5. In cases where the correct fan speed is not achieved, first check the pressure compensator, then check proportional
valve MA202 (positioned on the central valve).
It is possible to measure the output pressure to the cooling fan at the pressure outlet on the central valve. (The
pressure should normally not be below 150 bar (218 psi) when checking).
NOTE!