Volvo L120H Wheel Loader Workshop Repair Service Manual PDF Download - MVLVCOL120H.zip
This is a full workshop service and repair manual, complete with electrical wiring diagrams, covering the Volvo L120H Wheel Loader. It contains every technical detail needed to service, troubleshoot, fix, and rebuild the machine to professional standards.
The Volvo Construction Equipment L120H Wheel Loader workshop service and repair manual covers the following:
* 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 L120H Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,603 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
000 - GENERAL......2
03 - SPECIFICATIONS......3
Tightening torques......4
Conversion tables......15
07 - STANDARD TIME......19
Operation numbers for additional work......20
08 - TOOL......22
E 1708; Checking point......23
E1711......25
E-2001......27
E-2005......29
E-2010......31
E-2014......32
E-2015......34
E-2017......36
E-2019......37
Infrared Thermometer......39
Leak detector 951 1207; description......43
88830557 User Instruction......47
001 - STANDARD PARTS; SERVICE......57
16 - LUBRICANT; FUEL; OTHER FLUID......58
AdBlue®_DEF......59
Coolant......65
Recommended lubricants_{10-31-02}......67
Recommended lubricants_{10-30-37}......72
Alternative fuels......76
17 - SERVICE......79
Service......82
Arrival Inspection; according to Inspection Programme......85
Delivery Inspection; according to Inspection Programme......86
Maintenance of Stored Machines; according to Inspection Programme......87
Maintenance service; first 500 hours......88
Maintenance service; first 1000 hours......89
Maintenance service; every 50 hours......90
Maintenance service; every 250 hours......91
Maintenance service; every 500 hours_{10-25-50}......92
Maintenance service; every 500 hours_{10-25-30}......94
Maintenance service; every 1000 hours_{10-24-54}......96
Maintenance service; every 1000 hours_{10-24-34}......99
Maintenance service; every 2000 hours_{10-23-45}......102
Maintenance service; every 2000 hours_{10-23-26}......106
Maintenance service; every 4000 hours_{10-22-31}......110
Maintenance service; every 4000 hours_{10-22-11}......114
Maintenance service; every 6000 hours_{10-20-59}......118
Maintenance service; every 6000 hours_{10-20-39}......119
Maintenance service; every 8000 hours_{10-20-08}......120
Maintenance service; every 8000 hours_{10-19-48}......121
Service position 1......122
Service position 2......125
Restoring of the machine......128
Lubrication; every 50 hours......129
Lubrication; every 250 hours......132
Lubrication; every 500 hours......137
Lubrication; every 1000 hours......139
Hinge; lubricating......141
Basic service......144
Engine belt condition; checking......145
Valves; adjusting-......147
Engine oil level; checking......155
Engine oil and filter; changing_{10-13-11}......156
Engine oil and filter; changing_{10-12-48}......159
Fuel filters; replacing......162
Fuel tank breather filter; replacing......164
Diesel particulate filter; regenerating......165
Diesel particulate filter; checking and cleaning......166
AdBlue®_DEF pump unit filter; replacing......172
AdBlue®_DEF tank breather filter; replacing......175
Engine air cleaner primary filter; replacing......177
Engine air cleaner secondary filter; replacing......179
Oil-bath air cleaner reservoir oil; checking......181
Oil-bath air cleaner reservoir oil; changing......184
Oil-bath air cleaner reservoir filter insert; cleaning......187
Coolant level; checking......189
Coolant; changing......190
Coolant freezing point; checking......192
Coolers; cleaning......194
MATRIS and Tech Tool; reading......196
Software update; checking......197
Battery; checking......201
Transmission; calibrating......203
Transmission oil level; checking......204
Transmission oil; filter and suction strainer; changing and cleaning_{10-02-17}......205
Transmission oil; filter and suction strainer; changing and cleaning_{10-01-54}......210
Drive axle oil; changing......215
Rear axle bearing oil; changing......218
Rear axle pivot bearing; greasing......220
Axle breather filters; replacing......221
Service brake disc wear; checking......223
Service brake; testing......226
Brake pressure and function; checking......228
Axle oil cooler filter; replacing......230
Parking brake pads; checking......232
Parking brake function; checking ......234
Tyre wear and air pressure; checking......235
Alternative exit; checking......237
Cab prefilter; replacing......239
Cab main filter; replacing......241
Cab extra prefilter cyclone type; replacing......243
Hydraulic oil level; checking......245
Hydraulic oil; changing......246
Hydraulic oil tank breather filter; replacing......249
Hydraulic tank sediment; draining......250
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{09-52-31}......252
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{09-52-09}......254
Hydraulic pressure; checking......256
Boom suspension accumulator; checking......259
Fire suppression system; checking......265
Automatic central lubrication filter; replacing......285
Parking brake; manually releasing_{09-49-13}......287
Parking brake; manually releasing_{09-48-51}......289
Parking brake; manually releasing_{09-48-23}......292
Parking brake; manually releasing_{09-48-00}......294
Towing......297
19 - GENERAL......300
Working on the electrical system of the machine......301
CE-marking; EMC-directive......303
Safety concerns everybody!......307
Checking function......311
Safety when handling the machine......312
Safety rules when servicing......317
Service position 2_{09-43-28}......320
Service position 1_{09-43-08}......322
Working under raised boom......324
Fire prevention measures......326
Some simple rules regarding tyre handling......330
Safety when lifting and supporting complete machine......332
Safety when working with batteries......336
Starting with booster batteries......339
Safety when handling oils and fuel......342
Safety when working on hydraulic systems......344
Checklist after a fire or heat exposure......346
Health hazards with paint; plastics and rubber......349
Environmental handling for the future......352
Waste handling......355
Environmentally safe handling......359
Environmentally hazardous fluids......362
Safety when working with air conditioning refrigerant......365
Working in environmentally contaminated areas......368
Decontamination......371
002 - ENGINE WITH MOUNTING AND EQUIPMENT......375
20 - GENERAL......376
Engine; description_{09-34-35}......377
Engine; description_{09-34-02}......384
Engine; description_{09-33-33}......391
Tech Tool; operations_{09-32-41}......398
Engine control module (ECM); replacing pre-programmed......400
Engine control module (ECM); replacing non-programmed......402
Engine; capacities......404
Engine belts; replacing......405
Engine; reference values......408
21 - ENGINE......411
Engine; specifications......412
Engine; removing......413
Engine; installing......428
Engine; replacing_{09-27-48}......443
Engine; replacing_{09-27-29}......447
Engine; tightening torques......450
Cylinder compression; testing......455
Crankcase ventilation; description......458
Valve mechanism; specifications......462
Valves; adjusting......464
Engine mounting rear; changing......472
22 - LUBRICATING SYSTEM......479
Lubricating system; description......480
Lubrication system; specifications......485
Lubrication oil consumption; checking......487
Lubrication system; component locations......491
Lubrication system; tightening torques......494
Lubrication oil pressure; checking with pressure gauge......497
23 - FUEL SYSTEM......499
Fuel system; description......500
Fuel system; specifications......507
Fuel system; tightening torques......509
Carbon dioxide in fuel system; checking......516
Fuel system basics; checking......522
Fuel system; component location......525
Feed pump pressure; checking......528
Fuel system; bleeding......530
Fuel tank; volume......532
Stall speed; checking......533
Injectors; replacing......536
Injector sleeves; replacing......544
Fuel rail; replacing......553
Fuel rail pressure sensor; replacing......559
High pressure fuel pump; replacing......561
High pressure fuel pipes; replacing......567
Fuel control valve (FCV); replacing......573
Pressure relief valve (PRV); replacing_{09-07-47}......578
Pressure relief valve (PRV); replacing_{09-07-25}......581
25 - INLET & EXHAUST SYSTEM......584
Inlet and exhaust system; description......586
Inlet and exhaust system; specification......592
Inlet and exhaust system; component location......594
Inlet and exhaust system; tightening torques......597
Exhaust pipe flexible tube; replacing......602
Auxiliary brake (engine braking); description......604
Exhaust Aftertreatment System; description......606
Exhaust Aftertreatment System; component location......620
Regeneration process; description......624
AdBlue®_DEF tank; volume......631
AdBlue®_DEF dosing injector; replacing......632
AdBlue®_DEF mixing tube; replacing......635
AdBlue®_DEF tank; replacing......639
AdBlue®_DEF; draining......649
Coolant valve; replacing......654
SCR (Selective catalytic reduction) muffler; replacing......656
AdBlue®_DEF quality; checking......661
SCR (Selective catalytic reduction) dosing system; checking......665
AdBlue®_DEF pump unit diagnostics; description......668
DPF (Diesel particulate filter); checking and cleaning......672
ACM (Aftertreatment control module) non-programmed; replacing......678
ACM (Aftertreatment control module) pre-programmed; replacing......680
Inlet throttle; replacing......682
DOC (Diesel oxidation catalyst); replacing......684
AdBlue®_DEF pump unit; replacing......689
AdBlue®_DEF tank armature; replacing......692
AdBlue®_DEF tank armature; cleaning......694
AdBlue®_DEF tank armature suction filter; replacing......697
AdBlue®_DEF hoses; replacing......699
AdBlue®_DEF......705
Crystallization of AdBlue®_DEF; checking......711
AdBlue®_DEF pump unit; filter; replacing......716
AdBlue®_DEF pump unit; flushing......719
AdBlue®_DEF pump unit; inlet nipple; replacing......722
Regeneration log; checking......725
AdBlue®_DEF tank; cleaning......737
Turbocharger; replacing......742
Wastegate; checking......747
26 - COOLING SYSTEM......749
Cooling system; description......750
Cooling system; specifications......754
Carbon dioxide in coolant system; checking......755
Cooling system; component location......761
Cooling system; tightening torques......765
Coolant with anti-freeze and corrosion protection; recommendation......768
Cooling system pressure; checking......771
Radiator; replacing......773
Coolant pump; replacing......784
Thermostat; replacing......789
Cooling fan; component location......794
Cooling fan; description......797
Reversible cooling fan; description......803
Cooling fan motor; description......810
Cooling fan; tightening torques......812
Temperature limits for cooling fan speed; specifications......814
Cooling fan rpm; specifications......817
27 - ENGINE CONTROL......820
ECO - accelerator pedal......821
29 - MISCELLANEOUS......823
Exhaust Gas Recirculation (EGR); description......824
Exhaust gas recirculation (EGR); component location......831
EGR system; tightening torques......834
EGR reed valve; replacing......836
EGR cooler; replacing......839
EGR valve; replacing......841
EGR venturi tube; replacing......843
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......845
30 - GENERAL......846
Electrical system; work instructions......855
Electrical system; tightening torques......857
Electrical system; description......862
Electronic control system; description_{08-29-55}......864
Electronic control system; description_{08-29-29}......871
Electrical system; specifications......878
Tech Tool; operations-......879
Limp home function; description......880
Software parameters; description......882
General fault diagnosis information......896
Troubleshooting strategy......898
Collection of basic data......900
Conditions when checking......903
Lead and connector checks......906
Troubleshooting tools......911
Tech Tool; operations ......913
AL3201; description and measuring......915
BB1 Communication bus; description and measuring_{08-22-01}......918
BB1 Communication bus; description and measuring_{08-21-23}......922
BB2 Communication bus; description and measuring_{08-20-30}......926
BB2 Communication bus; description and measuring_{08-19-43}......930
CU3602; description and measuring......934
CU3605; description and measuring......937
CU6601; description and measuring_{08-16-52}......939
CU6601; description and measuring_{08-15-56}......945
CU9901; description and measuring_{08-14-55}......951