Volvo L120D Wheel Loader Repair Manual

Table of Content L120D Service Information

GENERAL
DESCRIPTION, COMPLETE MACHINE
General
Product identification plates
General
Tightening torques
Tightening torques
Volvo standard tightening torques
TRANSPORT INSTRUCTION.; STORAGE INSTRUCTION; OPERATING INSTRUCTION
General
Transporting the machine
STANDARD TIME
General
TOOL
General

Section 4 Power transmission

STANDARD PARTS, SERVICE
LUBRICANT; FUEL; OTHER FLUID
General
Recommended lubricants
SERVICE
Maintenance
Charging of batteries
Cleanliness, brake and hydraulic systems
Repairing the hydraulic system
Safety filter (secondary filter)
Emergency measures
Manual release of parking brake, L90D
(later version)
Manual release of parking brake, L120D
Manual release of parking brake, L90D
Starting with booster batteries
Transporting wheel loader on another vehicle
ENGINE WITH MOUNTING AND EQUIPMENT
GENERAL
General, engine installation and its function
Engine, installing
Specifications, tightening torques
Specifications, capacities
Specifications, general
Specifications, tightening torques
ENGINE
Cylinder head
Description, cylinder head
Cylinder block with crankcase ventilation
Description, pistons and piston rings, L90D
Description, cylinder block
Valve mechanism
Engine transmission; camshaft
Description, engine transmission
Crank shaft; connecting rod; vibration damper; fly wheel
Description, crankshaft
LUBRICATING SYSTEM
General, common info about 221 – 224
Description, lubrication and oil system
Specifications, L120D
Oil cooler
Oil cooler, description
FUEL SYSTEM
General (common info about 233 – 238)
Description, general
Fuel pump; filter; strainer
Fuel tank; fuel filling pump
Specifications, capacities, L120D
Injection pump; regulator; pump companion
Injection timing, checking and setting
Specifications, general, L120D
Injector; delivery pipe
Copper tubes for injectors, changing
INLET SYSTEM; EXHAUST SYSTEM
Turbo charger
Air cleaner with connections; air pre-heater
Specifications, air cleaner
COOLING SYSTEM
General, common info about 261 – 269
Radiator, mounting and connections included
Radiator, removing and installing
Coolant pump; thermostat
Coolant pump for Intercooler,
removing and installing
Hydraulically driven cooling fan,
checking and adjusting speed
Hydraulically driven cooling fan L120D, description
Hydraulically driven cooling fan,
checking and adjusting max. pressure
ENGINE CONTROL
Stop control
Stop solenoid, adjusting stroke
Stop solenoid, troubleshooting advice
ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
GENERAL
Comprehensive info, electrical system
2 Software functions, engine
3 Software functions, electrical system
4 Software functions, power transmission
5 Software functions, brakes
6 Software functions, steering system
9 Software functions, hydraulic system
Air filter pressure
APS II
Axle oil temperature
Back-up alarm
Boom Suspension System (BSS)
Brake pressure
Brake test
Break in computer communication
Central lubrication
Communication with data buses
Control units, software functions
Coolant temperature, engine
Coolant temperature, outlet, radiator
(L120D with hydraulically driven radiator fan)
Description of software functions table
Differential lock
Downshift audible signal (beep)
Electrical system, description
Electrical system, instructions for working on the electrical system
Electrical system, specifications
Electronic control system, description
Engine oil pressure
Engine Shut Down (power reduction)
Engine Shutdown
Engine speed for V-ECU
Fuel level
Gear selector
Gearshifting solenoids
Hydraulic oil temperature
(L120D with hydraulically driven radiator fan)
Instrument control unit I-ECU, functional description
Interval wiper
Limp-Home, by-passed V-ECU
Output brake pressure
Overspeed transmission
Parking brake, electric
Parking brake, mechanical (L90D)
Preheating of induction air
Radiator fan control
(L120D with hydraulically driven radiator fan)
Reduced computer communication
Secondary steering
Service interval
Starter inhibitor
Starter motor engagement
System voltage
Transmission disengagement
Transmission oil filter
Transmission oil pressure
Transmission oil temperature
Travel speed
Tyre radius
Vehicle control unit V-ECU, functional description
Wiping during and after washing
BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
General, common info about 311 – 313
Battery, charging
Battery, description
Battery, specifications
ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
General, common info about 321 – 322
Alternator, description
Alternator, specifications
STARTING SYSTEM
General, common info about 331 – 334
Starter motor, specifications
Starting system, description
Electric air pre-heater, excluding element
Preheating, description
LIGHTING
General, common info about 351 – 356
Lighting, description
Lighting, specifications
CABLE; FUSE; RELAY
General, common info about 371 – 379
Chassis connections
Electrical components
Electrical symbols and designations
Explanations of cable and component markings
Key to communication cables
Positive feed
Signal earth
Wiring diagram 8.
Rotating beacon, direction indicators, brake lights
Wiring diagram 11.
Gearshifting solenoids, transmission disengagement
Wiring diagram 12.
Sensor transmission oil, mode selector, kickdown
Wiring diagram 19.
Heating, ventilation, air conditioning (AC)
Wiring diagram 22.
Work hydraulics, 3rd, 4th, 5th hydraulic functions
Wiring diagram 23.
Boom Suspension System (BSS), hydraulic oil temperature
Wiring diagram 32.
Mechanical parking brake with rider truck safety norms
Wiring diagram 32B.
Parking brake with rider truck safety norms
Electrical distribution box; fuse box; junction box
Electrical distribution box, description
INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
General, common info about 383 – 387
Warning/information unit, display unit
Display panel and keypad, general
Display panel, general
Display panel, information displays
Display panel, initial display
Display panel, operating display
Display panel, setting
Middle instrument panel with warning lamps
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 input sensor
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
POWER TRANSMISSION
GENERAL
General, common info about 410 – 436
Specifications, L90D
CLUTCH; TORQUE CONVERTER
Clutch control, manual or fixed
Specifications, L90D and L120D, general
Hydrodynamic coupling, torque converter
Specifications, L120D
TRANSMISSION, HYDRAULIC CONTROL
General
Specifications, capacities
Specifications, general
Specifications, weight
Transmission, hydraulic control
Clutch pressure chart, L90D∗
Clutch pressure chart, L120D∗
Gear selector valve, description
Hydraulic transmission, checking oil pressure
Symbol diagram, HT131, L90D
Symbol diagram, HT205, L120D
Transmission, installing
GEARBOX,
Distributing gearbox
Specifications, capacities
FRONT AXLE; REAR AXLE
General, common info about 461 – 468
Specifications, L90D, general
Specifications, L120D, general
Specifications, L120D, weight
Front axle
Front axle, installing
Specifications, L90D, capacities
Specifications, L120D, capacities
Rear axle 1
Rear axle, installing
Specifications, capacities
Differential lock, with control
Differential lock, adjusting
BRAKE
GENERAL
Comprehensive info about brakes
WHEEL BRAKE
General, common info about 511 – 519
Specifications, general
HYDRAULIC BRAKE SYSTEM
General, common info about 520 – 522
Brake system, bleeding
Brake system, retardation, checking function
Foot brake pedal, adjusting angle and pedal clearance
Pressure in circuit, checking and adjusting
Brake valve
Specifications, general
Brake accumulator; hydraulic pump
Discarded accumulators
Specifications, L120D, general
PARKING BRAKE
General, common info about 551 – 554
Parking brake (hydraulic), brake pad
replacement, later version
Parking brake (hydraulically controlled), checking and adjustment, later version
STEERING
GENERAL
Comprehensive info, steering
STEERING
General, common info about 641 – 647
Hydraulic diagram, steering,
from and including chassis no. 17372
Hydraulic diagram, steering, incl. lever steering (CDC)
Hydraulic diagram, steering, incl. lever steering (CDC)
and secondary steering
Hydraulic diagram, steering, incl. secondary steering
Hydraulic diagram, steering, from and
including chassis no. 14445
Hydraulic diagram, steering, incl. lever steering (CDC)
Hydraulic diagram, steering, incl. lever steering (CDC) and secondary steering
Hydraulic diagram, steering, incl. secondary steering
Hydraulic equipment
Hold (stand-by) pressure and working pressure,
checking and adjusting
Shift valve L120D, description
Shift valve, reconditioning (removed)
Specification L120D, general
Steering pump, description
Steering valve, description
Supplementary steering
LEVER STEERING
General
Hydraulic system, description
Lever steering, checking and adjusting control valve
Wiring diagrams 17 and 9
FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
GENERAL
Comprehensive info about frame and track unit/wheels
FRAME
General, common info about 711 – 718
Specifications, tightening torques
Frame, complete
L120D specifications, weight
Protection; belly plate; bumper
Specifications, weight
Counterweight
L120D specifications, weight
WHEELS; TRACKS; TYRE; HUB; DRUM
General, common info about 771 – 775
L120D specifications, weight
MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
CAB, NAKED; CANOPY
General
Cab suspension, description
Cab, installing
Cab, removing
Tightening torques
AIR CONDITIONING UNIT
General, common info about 872 – 877
Cooling unit
Air conditioning, checking performance
Air-conditioning unit, specifications
Evaporator in the air-conditioning unit, cleaning
HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
WORKING HYDRAULICS; SERVO HYDRAULICS
General, common info about 911 – 917
Hydraulic diagram, working hydraulic system
Hydraulic diagram L90D, complete
Hydraulic diagram L120D, complete
Hydraulic diagram, working hydraulic system
incl. attachment locking and 3rd/4th function
Hydraulic diagram, working hydraulic system
incl. attachment locking and 3rd function
Specifications, L120D, capacities
Specifications, general
Working hydraulics
Shock and anti-cavitation valve
Specification L120D, general
Specification L90D, general
Specifications, L120D, capacities
Specifications, L90D, capacities
Specifications, weight
Pump, working hydraulics
Back-up valve, opening pressure, checking
L90D specifications, weight
L120D specifications, weight
Shock valve, lift function, checking and adjusting
Shock valve, tilt function, checking and adjusting
Specification L90D, general
Specification L120D, general
Specifications, tightening torques
Servo hydraulic system
Pressure back-up for servo circuit,
checking accumulator
Servo pressure, checking and adjusting
(machine with separate attachment locking)
Servo pressure, checking and adjusting
(machine without separate attachment locking)
Servo pressure, checking by spool in control valve
Servo valve, functional description
Specification L90D, general
Specification L120D, general
Specifications, weight
Other hydraulic equipment
Boom Suspension System (BSS400), checking function
Boom Suspension System (BSS400), electrical system description
Boom Suspension System (BSS400), hydraulic system description
Precharge pressure in accumulators,
checking and adjusting
Pressure reducing valve (CT8) for
Boom Suspension System, adjusting
Specification L120D, general
UNIT, LOAD HANDLING
Lifting frame work with mounting and link arm system
L90D specifications, weight
L120D specifications, weight
Specification L90D, general
Specification L120D, general
Specifications, tightening torques
Tilt cylinder