Volvo L120F Wheel Loader Service and Repair Manual PDF

Volvo L120F Wheel Loader Service and Repair Manual PDF

Size: 319.88 MB
Language: English
Make: Volvo
Machine: Wheel Loader
Document: Hydraulic and Electrical Diagram, Service and Repair Manual
Model: Volvo L120F
Page: 5152 Pages

Detail Contents:
1 Volvo L120F
Descriptions

• Accelerator Pedal
  Air cleaner, description
  Air conditioning, description
  Automatic differential brake, Limited Slip, description
  Basic checks
  Battery disconnector switch, description
  Boom Suspension System, component description
  Boom Suspension System, description
  Booting sequence
  Brake accumulator, description
  Brake system, component location
  Braking system, description
  Bus communication supervision
  CareTrack W-ECU, description
  Central lubrication system, description 1
  Central lubrication system, description
  Central valve, description
  Change of lubrication interval
  Charging of batteries
  Climate control unit ECC, description
  Collection of basic data
  Connectors, overview
  Control valve, description
  Cooling fan motor, description
  Cooling fan, component location
  Cooling fan, description
  Cooling system, description
  Diagnostic tools, description
  Differential lock, description
  Dosage valves, description
  Drive axles, description
  Electric welding
  Electrical system, description
  Electrical system, work instructions
  Electronic control system, description
  Engine control unit E-ECU, description
  Engine, description
  Error codes, showing
  Filling lubricant
  Fire suppression system, component description
  Fire suppression system, functional description
  Floating position, description
  Foot brake valve, description
  Frame joint, description
  Frame, description
  Fuel consumption
  Fuel control valve (FCV), description
  Fuel feed pump, description
  Fuel filter, description
  Fuel rail, description
  Fuel system, description
  General fault diagnosis information
  Hand Throttle
  High pressure fuel pump, description
  Hydraulic attachment bracket, description
  Hydraulic oil tank, description
  Hydraulic pump flow regulation, description
  Hydraulic pumps, description
  Hydraulic system and component positions
  Hydraulic system, description
  Hydraulic transmission, description
  Information display, service
  Injectors, description
  Instructions for working with electronic fuel injection
  Instrument control unit I-ECU, description
  Instrument panels
  Intake and exhaust system, description
  Intercooler, description
  Intermittent wiper and washer
  Internal Exhaust Gas Recirculation (IEGR), description
  Lead and connector checks
  Lift function, description
  Lighting, description
  Limp Home
  Lubricating system, description
  Machine hours
  Middle instrument panel with warning lights
  Parameter settings
  Parking brake, description
  Pause heater, description
  Pause heater, description]
  Preheating, description
  Pressure monitor, description 1
  Pressure monitor, description
  Pump unit, description
  Reduced computer communication
  Reversible cooling fan, description
  SAE error codes, translation to error messages, general
  Shift valve, description 1
  Shift valve, description
  Software parameters, description
  Software, description
  Software, parameter settings and read-outs
  Steering cylinder, description
  Steering system, component location
  Steering system, description
  Steering valve, description
  Tech Tool, operations
  Theft protection
  Tilt function, description
  TP-Linkage’s bearing points
  Transmission, component position
  Travelling speed
  Troubleshooting strategy
  Troubleshooting tools
  Troubleshooting, air conditioning unit (AC)
  Turbocharger, description
  VCADS Pro service tool
  Vehicle control unit V2-ECU, description
  Vehicle control unit V-ECU, description
  Viscous cab suspension, description
  Washer fluid level
  Windows, general
  Working hydraulic system, component location
  Working hydraulic system, function description
  Working on the electrical system of the machine

Diagrams

• Explanations to hydraulic diagram
  Hydraulic diagram transmission
  Hydraulic diagram, complete 1
  Hydraulic diagram, complete 2
  Hydraulic diagram, complete
  Table of contents, wiring diagrams
  Wiring diagram 201
  Wiring diagram 202
  Wiring diagram 203
  Wiring diagram 204
  Wiring diagram 205
  Wiring diagram 206
  Wiring diagram 301 1
  Wiring diagram 301
  Wiring diagram 302 1
  Wiring diagram 302
  Wiring diagram 302-2
  Wiring diagram 303
  Wiring diagram 304
  Wiring diagram 305
  Wiring diagram 306
  Wiring diagram 308
  Wiring diagram 309
  Wiring diagram 310
  Wiring diagram 311
  Wiring diagram 311-1
  Wiring diagram 311-2
  Wiring diagram 312
  Wiring diagram 313
  Wiring diagram 314
  Wiring diagram 314-1
  Wiring diagram 315
  Wiring diagram 316
  Wiring diagram 317
  Wiring diagram 319
  Wiring diagram 401
  Wiring diagram 402
  Wiring diagram 403
  Wiring diagram 403-1
  Wiring diagram 404
  Wiring diagram 407
  Wiring diagram 408
  Wiring diagram 501
  Wiring diagram 501-1
  Wiring diagram 601
  Wiring diagram 601-1
  Wiring diagram 602
  Wiring diagram 602-1
  Wiring diagram 604
  Wiring diagram 801
  Wiring diagram 802
  Wiring diagram 804
  Wiring diagram 804-1
  Wiring diagram 805
  Wiring diagram 805-1
  Wiring diagram 806
  Wiring diagram 806-1
  Wiring diagram 807
  Wiring diagram 901
  Wiring diagram 901-1
  Wiring diagram 902
  Wiring diagram 902-1
  Wiring diagram 903
  Wiring diagram 904
  Wiring diagram 908
  Wiring diagram 909
  Wiring diagram 910
  Wiring diagram 911
  Wiring diagram 912
  Wiring diagram 912-1
  Wiring diagram 913
  Wiring diagram 915

Installation Instructions

• 3rd hydraulic function, electric-hydraulic, installing new
  3rd hydraulic function, installing new
  Attachment locking, installing new
  Attachment work light, installing new
  Automatic lift arm lowering (Return to dig), installing new
  Axle oil cooler and reversilble fan, installing new
  Boom suspension system, installing new
  Cab, air pre cleaner, installing new
  Care track
  Engine heater, installing new
  Forward view camera, installing new
  Front view mirror, installing new
  Fuel filter extra, installing new
  Hand throttle, instaling new
  Lever steering (CDC), electric, installing new
  Lever steering (CDC), hydraulic, installing new
  Oil-bath air cleaner
  Pre-cleaner oil-bath type
  Protection for lighting, front, installing new
  Radiator grill guard, installaing new
  Rear view camera, installing new
  Rotating beacon, installing new
  Single lever control, installing new
  Work light front, installing new

Repair

• 3rd 4th hydraulic function, checking and adjusting pressure
  3rd 4th hydraulic function, solenoid valve, replacing
  3rd-4th hydraulic function, shock valve, checking
  Accumulator removed, checking charging pressure
  Accumulator removed, checking
  Accumulator, boom suspension system, discarding
  Accumulator, check
  Accumulator, checking (pressure back-up for servo circuit)
  Accumulator, discarding
  Air mix door actuator, replacing
  Attachment locking, functional check
  Automatic lubrication pump unit, reconditioning
  Axle suspension, replacing bushes and seals
  Axle, installing
  Axle, removing
  Back-up valve, checking and adjusting
  Back-up valve, replacing
  Batteries, replacing
  Battery condition, check
  Bleeding air
  Boom suspension accumulator, check and adjusting
  Boom suspension accumulator, reconditioning
  Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
  Boom suspension system, pressure reduction, safety valve, checking and adjusting
  Boom suspension system, test drive with load
  Brake disc, replacing 1
  Brake disc, replacing rear
  Brake disc, replacing
  Brake discs, measuring wear
  Brake pedal, adjusting angle
  Brake piston, replacing seals 1
  Brake piston, replacing seals rear
  Brake piston, replacing seals
  Brake system, bleeding
  Brake system, check and adjusting pressure in circuit
  Brake system, checking function, hydraulic
  Brake system, checking function, retardation
  Cab, installing 1
  Cab, installing 2
  Cab, installing
  Cab, removing 1
  Cab, removing 2
  Cab, removing
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  Central valve, installation
  Central valve, removal
  Climate unit, installing
  Climate unit, removing
  Comfort drive control (CDC), angle sensor, changing
  Comfort drive control (CDC), solenoid valve, changing
  Comfort Drive Control, servo pressure, checking
  Compression test 2
  Compression test
  Compressor, replacing incl draining and filling
  Condenser, replacing incl draining and filling
  Control valve, installation
  Control valve, removal
  Cooling fan hydraulics, funktion check
  Cooling fan motor, replacing
  Crankshaft, replacing front oil seal
  Differential lock, adjusting
  Differential lock, function check
  Door lock cylinder, replacing
  Door lock, changing’
  ECC control unit, replacing 1
  ECC control unit, replacing
  ECC, MID 146, changing non-programmed ECU
  ECC, MID 146, changing pre-programmed ECU
  E-ECU, MID 128, changing non-programmed ECU
  E-ECU, MID 128, changing pre-programmed ECU
  Engine hood, installing
  Engine hood, removing
  Engine rotation speed sensor, replacing
  Engine, installing 1
  Engine, installing
  Engine, removing 1
  Engine, removing
  Error codes when calibrating hydraulic
  Error codes when calibrating steering
  Error codes when calibrating
  Evaporator, replacing incl draining and filling 1
  Evaporator, replacing incl draining and filling
  Expansion valve, replacing incl draining and filling
  Fan control valve, installing
  Fan control valve, removing
  Fan control valve, seal replacement
  Fan motor, replacing
  Feed pump, checking feed pressure
  Fire suppression system, actions after activation
  Fire suppression system, actions after manual activation
  Fire suppression system, component location
  Foot brake valve removed, reconditioning
  Foot brake valve, installation
  Foot brake valve, removal
  Front wheel, installation
  Front wheel, removal
  Fuel control valve (FCV), checking
  Fuel control valve (FCV), replacing
  Fuel filter, checking
  Fuel rail pressure sensor, replacing
  Fuel system, bleeding
  Fuel tank, installing
  Fuel tank, removing
  Heat control valve, replacing
  Heater core, replacing 1
  Heater core, replacing
  High pressure fuel pump, checking
  High pressure fuel pump, replacing
  Hub reduction, installing 1
  Hub reduction, installing
  Hub reduction, removing 1
  Hub reduction, removing
  Hub, replacing seal 1
  Hub, replacing seal
  hydraulic function, solenoid valve, replacing
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic power control valve, replacing
  Hydraulic pump P1 and P2, checking function
  Hydraulic pump P1, installation
  Hydraulic pump P1, removal
  Hydraulic pump P2, installation
  Hydraulic pump P2, removal
  Hydraulic pump P3, installation
  Hydraulic pump P3, removal
  Hydraulic pump, checking and adjusting max working pressure 1
  Hydraulic pump, checking and adjusting max working pressure
  Hydraulic pump, checking and adjusting standby pressure and working pressure
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic pump, power control checking
  Hydraulic system, bleeding
  I-ECU, MID 140, changing non-programmed ECU
  I-ECU, MID 140, changing pre-programmed ECU
  Injectors, replacing all 1
  Injectors, replacing all
  Lever steering (CDC), functional check
  Lift cylinder, repacking in machine
  Lift lower, angle sensor, changing
  Lift, functional check
  Lift, solenoid valve, changing
  Lifting time, checking 1
  Lifting time, checking
  Lower, solenoid valve, changing
  Lubrication oil pressure, checking with pressure gauge
  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 4000 hours
  Maintenance service, every 6000 hours
  Mechanical release of parking brake
  Operator’s seat, securing
  Parking brake, function checking
  Parking brake, replacing discs and seals
  Pressure relief valve (PRV), checking
  Pressure relief valve (PRV), replacing
  Pump 3 (P3) standby pressure, checking and adjusting (LS-line removed)
  Pump 3 (P3), max pressure and fan speed, checking and adjusting
  Radiator, installing
  Radiator, removing
  Rear wheel, installing
  Rear wheel, removing
  Receiver, replacing incl draining and filling 1
  Receiver, replacing incl draining and filling
  Seal for rear output shaft, replacing
  Secondary steering pump, checking and adjusting working pressure
  Servo accumulator, installation
  Servo accumulator, removal
  Servo pressure, checking and adjusting
  Servo pressure, checking at the spool in control valve 1
  Servo pressure, checking at the spool in control valve
  Servo valve, adjusting control
  Servo valve, installation
  Servo valve, removal
  Shift valve, checking
  Shift valve, installing
  Shift valve, removing
  Shock valve lift function, checking 1
  Shock valve lift function, checking
  Shock valve, tilt function, checking
  Side window, replacing
  Stall speed, checking
  Steering cylinder removed, reconditioning excl replacing bearings
  Steering cylinder, installing
  Steering cylinder, removing
  Steering cylinder, repacking
  Steering system, checking and adjusting working pressure
  Steering valve, replacing
  System test
  Temperature sensor cooling system, replacing
  Tilt cylinder, repacking in machine
  Tilt in out, angle sensor, changing
  Tilt in, solenoid valve, changing
  Tilt out, solenoid valve, changing
  Tilt, functional check
  Towing
  Transmission oil pressure, checking 1
  Transmission oil pressure, checking
  Transmission oil pressure, checking2
  Transmission pressure sensor, replacing
  Transmission solenoid, replacing
  Transmission, calibration
  Transmission, installing
  Transmission, removing
  Turbocharger, inspection
  Update of automatic lubrication system
  V2-ECU, MID 249, changing non-programmed ECU
  V2-ECU, MID 249, changing pre-programmed ECU
  Valves, adjusting
  VCADS Pro, Operations
  V-ECU, MID 187, changing non-programmed ECU
  V-ECU, MID 187, changing pre-programmed ECU
  Viscous cab suspension, changing one unit
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Windscreen, replacing

Safety

• CE-marking, EMC-directive
  Checking function
  Checklist after a fire or heat exposure
  Decontamination
  Environmentally safe handling
  Fire prevention measures
  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 lifting and supporting complete machine
  Safety when using lifting equipment
  Safety when working on hydraulic systems 1
  Safety when working on hydraulic systems
  Safety when working with air conditioning refrigerant
  Safety when working with batteries
  Service position 1
  Some simple rules regarding tyre handling 1
  Some simple rules regarding tyre handling
  Starting with booster batteries
  Waste handling
  Working under raised boom

Service Bulletins

• AC compressor, fill with oil
  Action to be taken in case of abnormal lubricating oil consumption
  Air bleeding of the central lubrication system
  Air in fuel system
  Air leaks at fuel feed pump
  Alternative lubricants for axles with wet brakes
  Automatic greasing systems of foreign manufacture
  Automatic shifting (APS)
  Automatic transmission lubricants
  Battery and alternator test procedure
  Boom Suspension System connection change
  Cable harness connector, engine
  Cables cut under operator seat
  CareTrack, new software update 2008.3.0, including new Conversion kit part numbers for E series haulers and F series loaders
  CDC function, disengaging
  CDC-system, product improvements
  Central lubrication 1
  Central lubrication, oxide on pins
  Central lubrication
  Central valve, replacing priority spool
  Changed fastening of manifold insulation
  Changes to turbo wastegate linkage
  Cleaning of the machine
  Comfort Drive Control (CDC)
  Connector protection for axle oil temperature sensor
  Control measurement for electric servo lever and tilt lift angle sensor
  Corrosion in wastegate actuator
  Cranking problems
  D- arm cracks
  D6 D7 Exhaust gas leakage into the cooling system
  D6E and D7E, high pressure pipe leakage
  DEF AdBlue AUS32 sampling, method
  Diesel fuels – quality and function
  Discontinued recommendation for usage of anti-corrosion agent in cooling system
  ECU improvements
  ECU, functional check
  ED-paint added in exterior parts
  Engine coolant expansion tank
  Erroneous signal from accelerator pedal
  Error code, check
  Exhaust insulation
  Exhaust leakage into fuel system D6-D7
  Fire suppression system
  Fork arms, information warranty matters, altered procedures
  Fuel pump (Tier 3) manufacturing process improvement
  Fuel sampling, method
  Gearshifting
  Ghost codes for F-series wheel loaders
  Greasing of hydraulic pump drive shaft
  Heater element
  Heater unit, external leakage
  Heating core for cab heating
  Hydraulic oil cooler
  Improved hour recorder
  Improved oil cooler housing
  Improved routing of steering cylinder hoses
  Improved turbo oil return pipe and clamp
  Improved wiper motor 1
  Improved wiper motor
  Incorrect symbol on lever carrier casing
  Injector yoke bolt
  Inoperative audible reverse alarms
  Instructions for crack in lifting frame
  Instructions for drilling in ROPS structure
  Instructions for shielded metal arc welding
  Introduction of new climate unit, HVAC II
  Introduction of protective plate over fuel tank
  Lamp bracket with rubber suspension
  Leakage at engine oil pump gasket 1
  Leakage at engine oil pump gasket
  Leaking cab heating element
  Limitation, TP-linkage
  Loctite added on plugs and cartridges on BSS-valve
  Longer hose
  Loose seat base
  New AC compressor
  New accelerator pedal with gold plated terminals
  New angle sensor installation for CDC
  New angle sensor installation, lift and tilt function
  New angle sensor kit introduced
  New BSS valve
  New cab heater element
  New CareTrack W-ECU2
  New condenser
  New engine oil level sensor
  New front and rear axles introduced
  New gas strut for cab door
  New gear lever combi-switch
  New hydraulic pump
  New location for fuel filter assembly
  New locking cylinder kit
  New main control valve with integrated BSS-connection ports
  New reverse alarm
  New sensor and new sensor installation
  New software update 2011.3.0 for CareTrack
  New software version 2008.6.0 and 2008.6.1
  New software version 2012.3.0
  New software version V2011.4.1
  New sound absorbers
  New steering valve
  New switch for attachment lock
  New system design to meet revised ISO 15998
  New temperature sensor
  New turbo with improved waste gate design
  New axle oils
  New V-ECU and V2-ECU
  New wiper arm and wiper motor
  Non – VCE buckets and attachments
  Oil analyses
  Oil sampling, method
  Operator adaptation of electric servo lever functions with VCADS Pro
  O-ring with improved fit between hydraulic pump and transmission
  Parameter changes in VCADS Pro
  Parking brake solenoid valve
  Parking brake switch
  Problems with leaking test port hoses
  Quality of illustrations in technical reports
  Radio band setting
  Rear vision system – activation of operator menu
  Recommendations for Oil Sampling Intervals
  Reinforced attachment bracket
  Repair instructions for attachments
  Repair report for central lubrication pumps
  Reporting of product misuse & near-miss report
  Reports
  Return to dig, lifting arms lowering positioner
  Reversible fan causing error codes
  Rust on fenders
  Seals
  Sensor, check
  Service solution, separate belts
  Shaking or vibration in the working hydraulics
  Software parameters, description
  Software release summary WLO F-models
  Springs and plugs for main control valve
  Thermostat failure (D4, D5, D6 & D7)
  Transmission components
  Transmission, introduced actions
  Troubleshooting hydraulic pumps
  Turbo hose routing considerations
  Turbo Hot Shutdown
  Tyres, various types
  Updates on turbocharger
  Warning decals
  Water intrusion in cab
  Windshield guard interferes with nipple

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

Specifications

• Alternator 80 A, specification
  Battery, specifications
  Battery, weight
  Boom Suspension System, specifications
  Boom Suspension System, tightening torques
  Brake accumulator, specifications
  Brake system, specifications
  Brake valve, tightening torques
  Cab, tightening torque
  Control valve, lever steering (CDC), specifications
  Control valve, specifications
  Conversion tables 1
  Conversion tables
  Cooling system, volume
  Electrical system, specifications
  Engine, capacities
  Engine, specifications
  Engine, tightening torques
  Engine, weight
  Frame, tightening torque
  Front and rear axles, specifications
  Front and rear axles, tightening torque
  Front and rear axles, volume 1
  Front and rear axles, volume
  Fuel feed pump, specifications
  Fuel system, specifications
  Fuel system, tightening torques
  Fuel tank, volume
  Hydraulic connections, tightening torques
  Hydraulic pump (P1), specifications
  Hydraulic pump (P2), specifications
  Hydraulic pump (P3), specifications
  Hydraulic system, volume
  Hydraulic transmission, specifications
  Hydraulic transmission, tightening torques
  Hydraulic transmission, volume
  Lift cylinder, tightening torques
  Lighting, specifications
  Lubrication system, specifications
  Oil sump, tightening torque
  Parking brake, specifications
  Preheating, specifications
  Propeller shaft, tightening torque
  Recommended lubricants, oils
  Reversible cooling fan, tightening torques
  Servo system, specifications
  Speed sensor, specifications
  Speed sensor, tightening torque
  Steering cylinder, tightening torque
  Steering, specifications
  Temperature limits for cooling fan speed, specifications.
  Thermostat, specifications
  Tilt cylinder, tightening torques
  Turbocharger, tightening torques
  Valve system specifications
  Wheel brake, specification 1
  Wheel brake, specification
  Wheel brake, tightening torques
  Wheel, tightening torque

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Time Guide Old generation
Time Guide Previous generation

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