Volvo L120E Wheel Loader Workshop Repair Service Manual PDF with Electrical Wiring Diagrams - MVLVCOL120E.zip
A full workshop service and repair guide for the Volvo L120E Wheel Loader, complete with Electrical Wiring Diagrams, offering every technical detail needed to service, troubleshoot, fix, and rebuild the machine the way a professional technician would.
The Volvo Construction Equipment L120E Wheel Loader workshop service and repair manual contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Volvo L120E Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,999 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
00 - DESCRIPTION; COMPLETE MACHINE................4
Description ................5
03 - SPECIFICATIONS................7
Tightening torques................10
Lubrication system; specifications................21
Fuel system; tightening torques................22
Cooling system; specifications................24
Engine; weight_{008-53-54}................25
Engine; specifications_{008-53-12}................26
Engine; volume................27
Injectors; specifications................28
Fuel tank; volume_{008-51-32}................29
Fuel feed pump; specifications_{008-50-53}................30
Lighting; specifications................31
Valve system specifications_{008-49-29}................32
Injection pump; specifications................33
Intercooler; specifications................34
Cooling system; specifications ................35
Cooling system; volume................36
Thermostat; specifications................37
Oil-bath air cleaner; volume-................38
Cooling fan motor; specifications................39
Cooling fan rpm; specifications................40
Engine; specifications_{008-44-05}................41
Speed sensor; tightening torque................43
Battery; specification................44
Battery; weight................45
Electrical system; specifications................46
Preheating; specifications................47
Alternator; specifications................48
Starter motor; specifications................49
Rear axle; tightening torques................50
Torque converter; specifications................51
Torque converter; weight................52
Torque converter; tightening torque................53
Hydraulic transmission; weight................54
Hydraulic transmission; specifications................55
Hydraulic transmission; volume................56
Propeller shaft; tightening torque................57
Front axle; specification................58
Front axle; weight................59
Front axle; tightening torque................60
Front axle; capacity................61
Rear axle; specification................62
Rear axle; weight................63
Rear axle; capacity................64
Parking brake; specifications................65
Front wheel brakes; specification................66
Front wheel brakes; tightening torques................67
Front wheel brakes; weight................68
Rear wheel brakes; tightening torques................69
Rear wheel brakes; specifications................70
Rear wheel brakes; weight................71
Brake valve; specifications................72
Brake accumulator; specifications................73
Brake accumulator; capacity................74
Parking brake; specifications ................75
Steering; specification................76
Steering; hydraulic equipment; tightening torques................77
Steering; hydraulic equipment; specifications................78
Frame; specifications................79
Frame; tightening torque................80
Counterweight; weight ................81
Wheels; specifications ................82
Wheel; tightening torque................83
Wheel; weight................84
Wheels; specifications................85
Cab; weight................86
Cab; tightening torques................87
Operator's seat; weight................88
Air distribution; specifications................89
Air conditioning; tightening torques................90
Air conditioning unit; specifications................91
Hydraulic system; volume................93
Central block; specifications................94
Function times; specifications................95
Hydraulic pump (P003); specifications................96
Servo system; specifications................97
Cooling fan rpm; specifications-................98
Control valve; specifications................99
Hydraulic pump (P001); specifications................100
Boom Suspension System; specifications................101
Boom Suspension System; tightening torques................102
Hydraulic pump (P002); specifications................103
Boom and cylinders; specifications................104
Central lubrication system; specifications................105
Hydraulic connections; tightening torques................107
Conversion tables................109
Engine; specifications_{008-09-11}................114
07 - STANDARD TIME................115
Operation numbers for additional work................116
08 - TOOL................118
E 1234; Nipple................119
E 1281 Nipple................120
E 1708; Checking point................121
E-2017................123
Infrared Thermometer................124
1 - STANDARD PARTS; SERVICE................128
16 - LUBRICANT; FUEL; OTHER FLUID................129
Recommended lubricants; oils................130
Alternative fuels................132
17 - SERVICE................135
Working on the electrical system of the machine................136
Repairing hydraulic system................137
Cleanliness; brake and hydraulic systems................138
Electric welding................139
Charging batteries................140
Warranty inspection 100 hours................141
Warranty inspection 1000 hours................155
Transmission oil pressure; checking_{007-37-46}................180
Transmission oil pressure; checking_{012-42-27}................185
Hydraulic pump; max working pressure; checking and adjusting ................190
Maintenance service; daily................194
Maintenance service; every 050 hours................196
Maintenance service; every 250 hours................201
Maintenance service; every 500 hours................211
Maintenance service; every 3000 hours................225
Maintenance service; every 1000 hours................228
Maintenance service; every 2000 hours................252
Maintenance service; every 4000 hours................283
Maintenance service; every 6000 hours................313
Fuel system; bleeding_{012-15-01}................315
Hydraulic pump; max working pressure; checking and adjusting-................317
Transmission oil pressure; checking_{012-13-13}................321
Transmission oil pressure; checking_{012-12-32}................326
Parking brake; manually releasing................331
Towing................333
19 - GENERAL................335
CE-marking; EMC-directive................336
Safety concerns everybody!_{012-08-46}................340
Safety concerns everybody!_{012-08-10}................344
Safety when handling the machine................346
Safety rules when servicing................351
Working under raised boom................355
Fire prevention measures................357
Some simple rules regarding tyre handling................361
Safety when lifting and supporting complete machine................363
Safety when working with batteries................367
Starting with booster batteries................370
Safety when handling oils and fuel................372
Safety when handling accumulators................374
Safety when working on hydraulic systems ................376
Safety when using lifting equipment................379
Checklist after a fire or heat exposure................381
Health hazards with paint; plastics and rubber................384
Environmental handling for the future................387
Waste handling................390
Environmentally safe handling................394
Environmentally hazardous fluids................397
Safety when working with air conditioning refrigerant................400
Working in environmentally contaminated areas................403
Decontamination................406
2 - ENGINE WITH MOUNTING AND EQUIPMENT................410
20 - GENERAL................411
Engine; description_{011-50-02}................412
Engine; description_{011-49-26}................414
21 - ENGINE................416
Engine; specifications_{011-48-37}................417
Engine; specifications_{011-48-05}................418
Engine; weight_{011-47-27}................419
Engine; volume................420
Engine; removing_{011-46-24}................421
Engine; installing_{011-45-05}................430
Engine; specifications_{011-43-45}................440
Cylinder compression; testing................441
Cylinder head; description................445
Cylinder head gasket; description................447
D007 cylinder block with crankcase ventilation; description and operation................448
Pistons; description................449
Cylinder liner; description................451
Valve system specifications_{011-37-44}................453
Valve system specifications_{011-37-13}................454
Valves; description................455
Valves; adjusting_{011-36-00}................456
Internal Exhaust Gas Recirculation (IEGR); description................462
Engine timing gear; description................467
Camshaft; description_{011-32-27}................468
Crankshaft; description................470
Connecting rod; description................472
Vibration damper; description_{011-29-46}................474
Crankshaft front oil seal; replacing_{011-29-00}................476
Oil pan; resealing................483
Engine mounting; description................487
Engine mounting; front; replacing................488
22 - LUBRICATING SYSTEM................508
Lubrication system; description................509
Lubrication system; specifications................511
Oil pump; description................512
Oil pressure; checking................514
23 - FUEL SYSTEM................516
Fuel system; description_{011-16-24}................518
Fuel system; description_{011-15-49}................520
Fuel system; tightening torques................522
Instructions for working with electronic fuel injection................524
Fuel system; bleeding_{011-14-16}................527
Fuel feed pump; specifications_{011-13-30}................529
Fuel feed pump; specifications_{011-13-00}................530
Fuel feed pump; description................531
Fuel filter; description................532
Feed pump pressure; checking_{011-11-11}................533
Fuel filter; checking................535
Fuel tank; volume_{011-09-56}................537
Fuel tank; volume_{011-09-25}................538
Injection pump; specifications................539
Stall speed; checking................540
Injectors; specifications................542
Injectors; description_{011-06-25}................543
Unit pump; description................545
Pump unit; replacing................550
Engine ECU; removing................554
Injectors; replacing_{011-02-35}................557
High pressure fuel pump; checking................559
Fuel rail; description................563
Fuel rail pressure sensor; replacing................565
High pressure fuel pump; replacing................567
Fuel control valve (FCV); checking................575
Fuel control valve (FCV); replacing................579
Pressure relief valve (PRV); inspecting................582
High pressure fuel pump; description................585
Pressure relief valve (PRV); replacing................587
Control unit; description_{010-55-38}................590
Control unit; description_{010-55-00}................592
25 - INLET & EXHAUST SYSTEM................594
Flexible hose; replacing................595
Turbocharger; description................597
Turbocharger; inspecting................598
Air cleaner; preheater; specifications................600
Oil-bath air cleaner; volume................601
Air cleaner; description................602
Preheating coil; description ................603
Preheating; specifications ................604
Intercooler; specifications ................605
Intercooler; specifications................606
26 - COOLING SYSTEM................607
Cooling system; volume................608
Cooling system; description................609
Cooling system; specifications ................612
Radiator; removing_{010-46-14}................613
Radiator; removing_{010-44-53}................618
Radiator; installing_{010-43-24}................623
Thermostat; specifications................627
Thermostat; replacing................628
Coolant pump; replacing................631
Cooling system; specifications................634
Reversible cooling fan_{010-37-54}................635
Reversible cooling fan_{010-37-22}................638
Hydraulic pump (P003); specifications ................641
Cooling fan rpm; specifications................642
Cooling fan motor; specifications................643
Reversible cooling fan; hydraulic diagram description................644
Reversible cooling fan; electric description................648
Fan speed control; description................649
Pump 003 (P3) standby pressure; checking................654
Cooling fan hydraulics; function check................657
Pump 003 (P3) Fan pump_Brake pump Fan; check max pressure................659
Pump 003 (P3) Cooling fan pump_Brake pump. Cooling fan; checking max. rpm................662
Reversible cooling fan; trouble-shooting _ fault indication................665
Cooling fan motor; replacing................666
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................674
30 - GENERAL................675
Electrical system; work instructions................683
Electrical system; description ................685
Software; description................689
Electronic control system; description................690
Communication with data buses ................692
System voltage................694
Electrical system; specifications................695
Software functions per function group................696
Description of table for software functions................699
Engine oil pressure_{10-21-37}................700
Engine Oil Level................701
Fuel Level_{10-20-18}................702
Fuel Level_{10-19-53}................703
Fuel temperature................704
Protection for high fuel temperature; common rail................705
Water in fuel................707
Unit pumps................708
Injectors................709
Air filter pressure................710
Temperature induction air................711
Charge-air temperature_{10-16-18}................712
Boost pressure................713