Volvo L120E Wheel Loader Service and Repair Manual PDF

Size: 140.53 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L120E

US $50
Categories: Manual,Heavy Equipment
Brands: Volvo

Description

Volvo L120E Wheel Loader Service and Repair Manual PDF

Size: 140.53 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Service and Repair Manual, Hydraulic and Electrical Diagram
Model: Volvo L120E
Page: 4823 Pages

Detail Contents:
1.L120E
Descriptions

  • Abbreviations, wiring diagrams
    Accelerator Pedal
    Air cleaner, description
    Air filter pressure
    Alternator, description
    APS II
    APS
    Attachment locking
    Automatic engine shut-off
    Automatic lift arm lowering (Return to dig)
    Axle oil temperature
    Back-up alarm
    Barometric pressure
    Battery, description
    Boom Suspension System (BSS)
    Boost pressure
    Brake pressure charging
    Brake pressure
    Brake test
    Cable and component designations
    Cable and component marking explanations
    Camshaft speed
    Camshaft, description
    Central lubrication, status indication
    Central lubrication
    Charge-air temperature
    Charging batteries
    Cleanliness, brake and hydraulic systems
    Comfort Drive Control, description
    Communication cable explanation
    Component list 1 Alternator, batteries, capacitors, electronic units
    Component list 2 Diodes
    Component list 3 Fuses
    Component list 4 Heating coils, instruments, service connections
    Component list 5 Lights
    Component list 6 Control lights warning lights
    Component list 7 Solenoid valves
    Component list 9 Relays
    Component list 10 Signals, shift solenoids
    Component list 11 Sensors
    Component list 12 Switches
    Component list Motors, resistors, monitoring system
    Connecting rod, description
    Connectors, overview
    Connectors, position
    Control unit, description 1
    Control unit, description
    Control valve, description FIG1
    Control valve, description
    Coolant Level
    Coolant temperature, engine
    Coolant temperature, outlet radiator
    Cooling fan adjustment
    Cooling system, description
    Cooling system, description1
    Crankshaft, description
    Cylinder head gasket, description
    Cylinder head, description
    Cylinder liner, description
    D7 cylinder block with crankcase ventilation, description and operation
    Description of table for software functions
    Description torque converter
    Description
    Differential lock
    Display panel and keypad, general
    Display panel, information displays
    Display panel, initial display
    Display panel, operating display
    Downshifting signal
    Electric welding
    Electrical distribution box, description
    Electrical symbols and designations
    Electrical system, description
    Electrical system, work instructions
    Electronic control system, description
    Engine control unit E-ECU, description
    Engine mounting, description
    Engine Oil Level
    Engine oil pressure
    Engine Protection
    Engine Shutdown
    Engine speed for E-ECU
    Engine speed for V-ECU
    Engine timing gear, description
    Engine, description 1
    Engine, description 2
    Engine, description
    Exhaust Gas Recirculation (EGR)
    Fan speed control, description
    Foot brake valve, description
    Frame ground connections and signal ground
    Frame, description
    Fuel consumption
    Fuel feed pump, description
    Fuel filter, description
    Fuel Level
    Fuel rail, description
    Fuel system, description
    Fuel temperature
    Fully automatic
    Gear Selector
    Gearshifting solenoids
    General description
    Hand Throttle
    High pressure fuel pump, description
    Hydraulic Oil Level
    Hydraulic oil temperature
    Hydraulic power limitation
    Hydraulic pump, description FIG1
    Hydraulic pump, description
    Hydraulic system, description FIG1
    Hydraulic system, description
    Increased engine rpm
    Increased fan speed for AC
    Indication of serious engine fault
    Information display unit, general
    Information display unit, setting
    Injectors, description
    Injectors
    Instructions for working with electronic fuel injection
    Instrument control unit I-ECU, description
    Instruments
    Internal Exhaust Gas Recirculation (IEGR), description
    Interruption in computer communication
    Interval Wiper
    Key feed
    Lighting, description
    Lubrication system, description
    Mechanical release of parking brake
    Middle instrument panel with warning lights
    Oil pump, description
    Outdoor temperature
    Output brake pressure
    Overspeed, transmission
    Parking brake, description
    Parking brake
    Pistons, description
    Preheating coil, description
    Preheating of inlet air
    Protection for high fuel temperature, common rail
    Recommended lubricants, oils
    Reduced computer communication
    Repairing hydraulic system
    Reversible cooling fan, electric description
    Reversible cooling fan, hydraulic diagram description
    Reversible cooling fan, trouble-shooting fault indication.
    Reversible cooling fan
    Secondary steering, description
    Secondary steering
    Service display unit, axles and brakes
    Service display unit, electrical control input signals 1
    Service display unit, electrical control input signals 2
    Service display unit, electrical control input signals 3
    Service display unit, electrical control output signals 1
    Service display unit, electrical control output signals 2
    Service display unit, electrical system battery voltage
    Service display unit, engine
    Service display unit, general
    Service display unit, hydraulics
    Service display unit, settings
    Service display unit, transmission
    Service interval
    Service panel, electrical feed sensor
    Setting software parameters
    Shift valve, description
    Shift valve, function description
    Soft start and safety for AC
    Software functions per function group
    Software, description
    Speed limitation for lever steering (CDC)
    Speed limitation
    Starter motor engagement
    Starting system, description
    Steering cylinder, sectional view
    Steering valve, description
    Steering, description
    Steering, function description
    System voltage
    Temperature induction air
    Theft protection
    Time-controlled high idle
    Tire radius
    Transmission disengagement
    Transmission oil filter
    Transmission oil level’
    Transmission oil pressure
    Transmission oil temperature
    Transmission protection
    Transmission slipping
    Travelling speed
    Turbine speed
    Turbocharger, description
    Unit pump, description
    Unit pumps
    Valves, description
    Vehicle control unit V-ECU, description
    Vibration damper, description
    Vibration damper, description1
    Voltage feed E-ECU, I-ECU, V-ECU
    Voltage feed for sensors
    Warming of hydraulic oil
    Washer fluid level
    Water in fuel
    Wear indicator, description
    Wiping during and after washing
    Working on the electrical system of the machine

Diagrams

  • Circuit list
    Explanations to hydraulic diagram
    Hydraulic diagram, complete fig1
    Hydraulic diagram, complete
    Hydraulic diagram, fan, brake system fig 1
    Hydraulic diagram, fan, brake system
    Hydraulic diagram, reversible fan, brake system fig1
    Hydraulic diagram, reversible fan, brake system
    Hydraulic diagram, steering fig1
    Hydraulic diagram, steering with CDC and secondary steering 1 fig1
    Hydraulic diagram, steering with CDC and secondary steering 1
    Hydraulic diagram, steering with CDC and secondary steering fig1
    Hydraulic diagram, steering with CDC and secondary steering
    Hydraulic diagram, steering
    Hydraulic diagram, working hydraulics, differential lock fig1
    Hydraulic diagram, working hydraulics, differential lock, BSS fig1
    Hydraulic diagram, working hydraulics, differential lock, BSS, attachment lock, 3rd 4th function fig1
    Hydraulic diagram, working hydraulics, differential lock, BSS, attachment lock, 3rd 4th function
    Hydraulic diagram, working hydraulics, differential lock, BSS
    Hydraulic diagram, working hydraulics, differential lock
    Wiring diagram 1
    Wiring diagram 2
    Wiring diagram 3
    Wiring diagram 4
    Wiring diagram 5
    Wiring diagram 6
    Wiring diagram 7.1
    Wiring diagram 7.2
    Wiring diagram 8
    Wiring diagram 9
    Wiring diagram 9B
    Wiring diagram 10
    Wiring diagram 11
    Wiring diagram 12
    Wiring diagram 13
    Wiring diagram 15B
    Wiring diagram 16
    Wiring diagram 17 Updateted CDC
    Wiring diagram 17
    Wiring diagram 18
    Wiring diagram 19
    Wiring diagram 19C
    Wiring diagram 20
    Wiring diagram 21B
    Wiring diagram 21C
    Wiring diagram 22
    Wiring diagram 23
    Wiring diagram 24
    Wiring diagram 25
    Wiring diagram 26
    Wiring diagram 27
    Wiring diagram 28
    Wiring diagram 29
    Wiring diagram 30
    Wiring diagram 31
    Wiring diagram 32
    Wiring diagram 33
    Wiring diagram 34
    Wiring diagram 35
    Wiring diagram 101
    Wiring diagram 102
    Wiring diagram 103
    Wiring diagram 107

Installation Instructions

  • 3rd hydraulic function retaining function
    AC Electric fan
    Attachment lock
    Care track 1
    Care track
    Engine heater 120V 1250W
    Front working lights
    Heat insulation kit
    Lever steering
    Mounting kit, wide seat
    Oil-bath air cleaner
    Radio kit, right
    Return to dig
    Reversible fan
    Single lever control
    Tail lamp guard

Repair

  • 3rd, alternatively 3rd-4th hydraulic function, max. pressure, checking and adjusting
    AC relay-controlled, description
    AC software-controlled, description
    Accumulator, checking (removed)
    Air conditioning, checking performance
    Air conditioning, description
    Air conditioning, troubleshooting, software-controlled ATC
    ATC, description
    Attachment bracket cylinder, reconditioning
    Attachment locking hydraulic cylinder (vision-optimised bracket), replacing
    Battery, changing
    Battery, charging
    Boom suspension system, accumulator, changing
    Boom Suspension System, component description
    Boom Suspension System, description of function
    Boom Suspension System, description
    Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
    Boom Suspension System, pressure-reducing valve, adjusting
    Boom suspension system, reconditioning accumulator
    Boom suspension system, test drive with load
    Boom Suspension System, troubleshooting
    Boom, description
    Brake discs, changing
    Brake discs, checking wear
    Brake system, bleeding
    Brake system, checking hydraulic function
    Brake system, retardation, checking function
    Cab suspension, description
    Cab, description
    Cab, installing
    Cab, removing
    Central block, description
    Central lubrication system, description
    Charging batteries
    Checking LS-pressure for pump 1 (P1) and pump 2 (P2)
    Components ac
    Components
    Compression test
    Control valve, description
    Coolant pump, replacing
    Cooling fan hydraulics, funktion check
    Cooling fan motor, replacing
    Counterweight, replacing
    Crankshaft, replacing front oil seal 1
    Crankshaft, replacing front oil seal
    Differential lock
    Discarded accumulators
    Drive shaft, changing
    Engine ECU, removing
    Engine hood, installing 1
    Engine hood, installing
    Engine hood, removing 1
    Engine hood, removing
    Engine mounting, front, replacing.
    Engine, description
    Engine, installing 1
    Engine, installing
    Engine, removing 1
    Engine, removing 2
    Engine, removing
    Engine, tightening torques
    Evaporator in air conditioning system, cleaning
    Fan motor, changing
    Feed pump, checking feed pressure 1
    Filler grease filter, cleaning (optional equipment)
    Final drive
    Flexible hose, replacing
    Flow control Pump 1 (P1) and Pump 2 (P2)
    Foot brake pedal, adjusting angle and pedal clearance fig1
    Foot brake pedal, adjusting angle and pedal clearance
    Foot brake valve removed, reconditioning
    Front axle, installing
    Front axle, removing
    Fuel control valve (FCV), checking
    Fuel control valve (FCV), replacing
    Fuel feed pressure, checking
    Fuel filter, checking
    Fuel rail pressure sensor, replacing
    Fuel system, bleeding 1
    Fuel system, bleeding
    Fuel system, bleeding1
    Function test, secondary steering
    Gear selector valve, measuring resistance of solenoids
    Gear selector valve, removing and installing 1
    Gear selector valve, removing and installing
    General description
    Heat control valve, changing
    Heater core, changing
    High pressure fuel pump, checking
    High pressure fuel pump, replacing
    Hub, changing seal
    Hub, changing seal1
    Hub, changing seal2′
    Hydraulic attachment lock (software-controlled), description
    Hydraulic attachment lock with raised servo pressure, description
    Hydraulic couplings, description
    Hydraulic oil tank, description
    Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
    Hydraulic pump, checking and adjusting max working pressure
    Hydraulic pump, checking and adjusting max working pressure1
    Hydraulic pump, checking and adjusting standby pressure
    Hydraulic pump, checking and adjusting standby pressure1
    Hydraulic system, bleeding
    Hydraulic system, description
    Implemental attachment hydraulic cylinder, replacing
    Injector, replacing
    Injectors, replacing all
    Lever steering CDC, checking steering signals
    Lever steering, adjusting steering speed
    Lever steering, checking and adjusting control valve
    Lifting cylinder 1
    Lifting cylinder
    Lubrication cycle, description
    Maintenance service, daily
    Maintenance service, every 50 hours
    Maintenance service, every 250 hours
    Maintenance service, every 500 hours
    Maintenance service, every 1000 hours
    Maintenance service, every 2000 hours
    Maintenance service, every 3000 hours
    Maintenance service, every 4000 hours
    Maintenance service, every 6000 hours
    Measuring axial and radial play, rear axle mounting
    Mechanical release of parking brake
    Oil pan, resealing
    Oil pressure, checking
    Parking brake, mechanical release
    Planetary gear
    Precharge pressure in accumulators, checking and adjusting
    Pressure in circuit, checking and adjusting
    Pressure monitor, description
    Pressure relief valve (PRV), checking
    Pressure relief valve (PRV), replacing
    Pump 3 (P3) Cooling fan pump Brake pump. Cooling fan, checking max. rpm
    Pump 3 (P3) Fan pump Brake pump Fan, check max pressure
    Pump 3 (P3) standby pressure, checking
    Pump 3 (P3) standby pressure, checking1
    Pump unit, replacing
    Radiator, installing 1
    Radiator, installing
    Radiator, removing 1
    Radiator, removing
    Rear axle, installing
    Rear axle, removing
    Return To Dig, component position
    Reversible cooling fan, funktion check
    Sensor for differential lock, adjusting
    Servo pressure, checking and adjusting
    Servo valve, operating controls, adjusting
    Servo valve, replacing
    Shift valve, checking
    Shock valve lift function, checking
    Shock valve, tilt function, checking
    Stall speed, checking
    Stand-by pressure Pump 1 (P1) and Pump 2 (P2), checking and adjusting
    Steer cylinder, left, changing
    Steering pressure, checking and adjusting
    Steering valve, reconditioning (removed)
    Steering valve, replacing
    Thermostat, replacing 1
    Thermostat, replacing
    Torque converter, removing, installing
    Towing
    Transmission oil pressure, checking 1
    Transmission oil pressure, checking
    Transmission oil pressure, checking1
    Transmission oil pressure, checking2
    Transmission oil pressure, checking3
    Transmission, installing
    Transmission, removing
    Turbocharger, inspection
    Valves, adjusting 1
    Valves, adjusting
    Viscous cab suspension, changing one unit
    Warranty inspection 100 hours
    Warranty inspection 1000 hours
    Wheel, removing and installing
    Working hydraulic system, component location
    Working hydraulic system, description
    Working hydraulics, troubleshooting
    Working pressure Pump 1 (P1) and Pump 2 (P2), checking and adjustment

Safety

  • CE-marking, EMC-directive
    Checklist after a fire or heat exposure
    Decontamination
    Environmental handling for the future
    Environmentally hazardous fluids
    Environmentally safe handling
    Health hazards with paint, plastics and rubber
    Safety concerns everybody!
    Safety when handling accumulators
    Safety when handling oils and fuel
    Safety when handling the machine
    Safety when using lifting equipment
    Safety when working on hydraulic systems
    Safety when working with air conditioning refrigerant
    Safety when working with batteries
    Some simple rules regarding tyre handling
    Starting with booster batteries
    Waste handling
    Working in environmentally contaminated areas
    Working under raised boom

Service Bulletins

  • AC compressor, fill with oil
    Action to be taken in case of abnormal lubricating oil consumption
    Alternative lubricants for axles with wet brakes
    Amendments in Service Manual Engine, D10B; Drive Axle, AWB 40B and Drive Axle, AWB 41 AWB 50
    Automatic greasing systems of foreign manufacture
    Automatic shifting (APS)
    Automatic transmission lubricants
    Battery and alternator test procedure
    Brake return spring moved
    Cable harness connector, engine
    CareTrack Telematics system
    D- arm cracks
    D6-D7 Exhaust gas leakage into the cooling system
    Decoding of radio
    Delayed idle as adjustable parameter
    Detecting leaks with inspection lamp
    Diesel fuels – quality and function
    Discontinued recommendation for usage of anti-corrosion agent in cooling system
    ECU, functional check
    Electrical air condition condenser fan
    Engine oil requirements
    Engine radiator
    Engine software release W0647 for L60E-L120E Tier 2Stage 2
    Exhaust insulation
    Exhaust leakage into fuel system D6-D7
    Final software version 2004 W35 for hardware 11184401 V-ECU
    Fork arms, information warranty matters, altered procedures
    Fuel in engine oil
    Fuel leak
    Fuel sampling, method
    Gear shifting, HTE-series transmissions
    Greasing of hydraulic pump drive shaft
    Hydraulic power control
    Improved attachment of fan grid
    Improved hour recorder
    Improved oil cooler housing
    Improved turbo oil return pipe and clamp
    Instructions for crack in lifting frame
    Instructions for drilling in ROPS structure
    Instructions for shielded metal arc welding
    Intercooler air duct, improved hose and seals
    Leakage at engine oil pump gasket
    Leakage of axle oil
    Limitation, TP-linkage
    Loose seat base
    Monitoring function for high rail pressure changed on Tier3 engines
    MS.Internal.Documents
    New alternator anchorage
    New BSS valve
    New camshaft sensor in new position
    New CareTrack W-ECU2
    New coolant
    New engine oil level sensor
    New engine software medium platform
    New hardware for E-ECU
    New hardware for V-ECU and software version R 2004 w 51
    New hydraulic oil filter
    New I-ECU introduction
    New rear axle
    New screws and washers for intercooler bracket
    New sensor for accelerator pedal
    New software for E-models
    New starter switch
    Non – VCE buckets and attachments
    Non-return valve on the fuel return hose
    Oil analyses
    Oil leakage, crankshaft (oil pump side) D4D-D7D
    Oil sump
    Oils for Volvos wheel loaders equipped with AWB axles (Axle Wet Brakes)
    O-rings with improved heat resistance
    Parking brake solenoid valve
    Position of orifice within the hydraulic pump compensator
    Quality measures for V-ECU
    Quality of illustrations in technical reports
    Raising and supporting machines (up to and including the E models)
    Recommendations for Oil Sampling Intervals
    Reinforced screw stud
    Repair instructions for attachments
    Repair instructions for turbo wastegate linkage
    Replaced fuel level sensor
    Replacement of throttle pedal pivot pin
    Replacement of turbocharger
    Replacing bracket and drive belt for AC-compressor
    Replacing operator seat shock absorber
    Replacing parking brake seal
    Replacing unit pump on engines D6D and D7D
    Reporting of product misuse & near-miss report
    Reports
    Seals
    Sensor, check
    Service solution, separate belts
    Specifications, stall speed
    Technique and procedures when replacing valve cover gasket
    Tyres, various types
    Volvo Product incident accident report & Interview Form
    Water separator improvement
    Work instruction for campaign WLO1203 – Reinforcement of rear frame’s center hinge bearing

Special tool catalog

  • General
    Index
    Hooks
    1. Enviroment and Safety equipment
    2. Measuring equipment
    3. Tightening and Loosening tools
    4. Lifting equipment
    5. Pullers and Pressing equipment
    6. Drifts
    7. Guide pins and Guide sleeves
    8. Pliers
    9. Fixtures
    10. Tech Tool
    11. Spare parts

Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation

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