Volvo L120G Wheel Loader Workshop Repair Service Manual PDF Electrical Wiring Diagrams - MVLVCOL120G.zip
This is a full service and repair manual, complete with electrical wiring diagrams, for the Volvo Construction L120G Wheel Loader. It contains every technical detail needed to service, troubleshoot, fix, and rebuild the machine just like a professional technician would.
Inside the Volvo L120G Wheel Loaders workshop service repair manual, you'll find:
* 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.
PRODUCT DETAILS:
Total Pages: 2,843 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo L120G Wheel Loaders Service Repair Manual.pdf
MAIN SECTIONS
000 - GENERAL.......2
03 - SPECIFICATIONS.......3
Tightening torques .......4
Engine; software specifications .......15
Valve mechanism; specifications .......18
Flywheel; tightening torques .......20
Oil sump; tightening torque .......23
Lubrication system; tightening torques .......25
Exhaust aftertreatment system; specifications .......27
Conversion tables.......29
Fuel system; specifications .......33
Lubrication system; specifications .......35
Engine; tightening torques .......37
Engine; specifications .......38
07 - STANDARD TIME.......39
Operation numbers for additional work.......40
08 - TOOL.......42
E 1708; Checking point.......43
E1711.......45
E-2000.......47
E-2001.......49
E-2010.......51
E-2015.......52
E-2017.......54
Infrared Thermometer.......55
Leak detector 951 1207; description.......59
88830557 User Instruction.......63
001 - STANDARD PARTS; SERVICE.......73
16 - LUBRICANT; FUEL; OTHER FLUID.......74
Coolant.......75
Recommended lubricants .......77
Alternative fuels.......80
17 - SERVICE.......83
Service.......86
Electric welding .......89
Arrival Inspection; according to Inspection Programme-[2051].......91
Arrival Inspection; according to Inspection Programme.......92
Delivery Inspection; according to Inspection Programme.......93
Maintenance of Stored Machines; according to Inspection Programme.......94
Maintenance service; first 1000 hours-[1926].......95
Maintenance service; first 1000 hours.......96
Maintenance service; every 50 hours.......97
Maintenance service; every 250 hours.......98
Maintenance service; every 500 hours.......99
Maintenance service; every 1000 hours.......101
Maintenance service; every 2000 hours.......103
Maintenance service; every 4000 hours.......105
Maintenance service; every 4500 hours.......108
Maintenance service; every 6000 hours_{09-16-12}.......109
Maintenance service; every 6000 hours_{09-15-52}.......110
Maintenance service; every 8000 hours.......111
Brake discs; measuring wear .......112
Wheel brakes function; checking .......115
Service position 2_{09-14-09}.......116
Service position 1_{09-13-46}.......118
Wheel brake; specification .......120
Drive axles; oil; draining.......121
Front axle; breather filter; replacing.......123
Axle oil cooler; front axle; filter; replacing.......124
Rear axle bearing; oil; draining.......126
Hydraulic oil tank; draining.......128
Transmission oil; draining.......130
Engine oil; draining.......132
Spark plug; replacing .......134
Valves; adjusting_{09-08-46}.......136
Valves; adjusting_{09-08-19}.......142
Oil plugs; installing.......148
Take the hose away from the draining point of engine oil and replace the cap.......149
Fuel filters; primary and secondary filter; replace.......150
Engine oil filter; replacing.......152
Fuel tank breather filter; replacing.......153
Axle oil cooler; rear axle; filter; replacing.......154
Engine air cleaner; replacing.......155
Transmission oil filter; replacing.......157
Transmission suction strainer; cleaning.......159
Automatic central lubrication; filter; cleaning_replacing.......160
Cab; extra prefilter; replacing.......162
Rear axle; breather filter; replace.......164
Engine oil; filling.......165
Drive belts; check .......166
Hydraulic tank and transmission; breathing filter; replacing.......167
Hydraulic oil tank; return oil filter; replace; and magnetic rod; clean.......168
Hydraulic oil; filling.......170
Transmission oil; filling.......172
Rear axle bearing; oil; filling.......174
Drive axles; oil; filling.......176
Cab; prefilter; replace when required.......178
Cab filter; replacing.......180
Warming up machine.......183
Transmission oil; checking level.......185
Hydraulic oil level; checking.......187
Engine oil level; checking.......189
Coolant level; checking.......190
Brake system charging; checking .......191
Steering system working pressure; checking and adjusting .......195
Boom suspension accumulator; checking and adjusting_{08-54-00}.......198
Boom suspension accumulator; checking and adjusting_{08-53-37}.......202
Hydraulic pump; standby pressure and working pressure; checking and adjusting .......206
Oil-bath air cleaner's reservoir (optional equipment); oil; check.......210
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change.......213
Oil bath air cleaner oil; changing.......216
Battery; cables and connections; check.......219
Engine radiator; oil cooler and condensor (if installed); clean.......221
Hinge; lubricating.......224
Restore the machine to original condition.......227
Coolant's freezing point; check.......228
Tyres; wear and air pressure; checking.......230
DPF (Diesel particulate filter); checking and cleaning .......231
Lubrication; 50 hours maintenance interval.......235
Lubrication; 250 hours maintenance interval.......238
Lubrication; 500 hours maintenance interval.......241
Lubrication; 1000 hours maintenance interval.......245
Lubrication; 2000 hours maintenance interval.......249
Lubrication; 4000 hours maintenance interval.......253
Maintenance service; fire suppression system.......257
Hydraulic oil tank; sediment drain.......274
Coolant; changing.......276
Rear axle pivot bearing; greasing.......279
Parking brake; manually releasing.......280
Towing.......282
Electric welding.......284
19 - GENERAL.......285
Working on the electrical system of the machine.......286
CE-marking; EMC-directive.......288
Safety concerns everybody!.......292
Checking function.......296
Safety when handling the machine.......297
Safety rules when servicing.......302
Service position 2_{08-36-55}.......305
Service position 1_{08-36-32}.......307
Working under raised boom.......309
Fire prevention measures.......311
Some simple rules regarding tyre handling.......315
Safety when lifting and supporting complete machine.......317
Safety when working with batteries.......321
Starting with booster batteries.......324
Safety when handling oils and fuel.......327
Safety when handling accumulators.......329
Safety when working on hydraulic systems.......331
Checklist after a fire or heat exposure.......333
Health hazards with paint; plastics and rubber.......336
Environmental handling for the future.......339
Waste handling.......342
Environmentally safe handling.......346
Environmentally hazardous fluids.......349
Safety when working with air conditioning refrigerant.......352
Working in environmentally contaminated areas.......355
Decontamination.......358
002 - ENGINE WITH MOUNTING AND EQUIPMENT.......362
20 - GENERAL.......363
Engine; description.......364
Engine; software specifications.......368
Component locations.......371
VCADS Pro; operations .......374
Engine; capacities.......376
Engine belts; replacing.......377
E-ECU MID 128 pre-programmed; replacing.......381
E-ECU MID 128 non-programmed; replacing.......384
21 - ENGINE.......387
Engine; specifications.......388
Engine rotation speed sensor (crank shaft); replacing.......389
Engine rotation speed sensor (camshaft); replacing.......394
Engine; removing.......397
Engine; installing.......412
Engine; tightening torques.......427
Cylinder compression; testing.......429
Crankcase ventilation; description.......436
Crankcase ventilation separator; replacing.......440
Valve mechanism; specifications.......442
Valves; adjusting_{08-17-11}.......444
Valves; adjusting_{08-16-48}.......450
Flywheel; tightening torques.......456
Crankshaft front oil seal; replacing.......460
Oil sump; tightening torque.......470
Engine mounting rear; changing.......473
22 - LUBRICATING SYSTEM.......479
Lubricating system; description.......480
Lubrication system; specifications.......485
Lubrication system; tightening torques.......487
Lubrication system; component locations.......489
Engine oil pressure; specification.......492
Lubrication oil pressure; checking with pressure gauge.......494
23 - FUEL SYSTEM.......496
Fuel system; description.......497
Fuel system; specifications.......504
Fuel system; tightening torques.......506
Carbon dioxide in fuel system; checking.......513
Fuel system; component location.......519
Feed pump pressure; checking_{08-05-41}.......521
Feed pump pressure; checking_{08-05-22}.......522
Fuel system; bleeding.......524
Fuel pump; replacing.......526
Stall speed; checking.......528
Injectors; replacing.......530
Injector sleeves; replacing.......536
Fuel rail pressure sensor; replacing.......545
High pressure fuel pump; replacing.......548
Fuel control valve (FCV); replacing.......551
Pressure relief valve (PRV); replacing.......557
High pressure fuel system pressure; relieving.......562
25 - INLET & EXHAUST SYSTEM.......564
Inlet and exhaust system; description.......566
Inlet and exhaust system; component location.......572
Inlet and exhaust system; tightening torques.......575
Exhaust pipe flexible tube; replacing.......576
Auxiliary brake (engine braking); description.......579
Exhaust Aftertreatment System; description.......581
Exhaust Aftertreatment System; component location.......593
Regeneration process; description.......596
Exhaust aftertreatment system; specifications.......601
DPF (Diesel particulate filter); checking and cleaning.......603
Exhaust aftertreatment system; tightening torques.......607
Spark plug control unit; replacing.......609
Glow plug; replacing.......611
Glow plug control unit; replacing.......613
Fuel metering unit A; replacing.......616
Fuel metering unit B; replacing.......621
Air pump safety valve; replacing.......626
ACM (Aftertreatment control module) non-programmed; replacing.......628
ACM (Aftertreatment control module) pre-programmed; replacing.......631
Spark plug; inspecting.......634
Spark plug; replacing.......636
Spark plug cable; replacing.......638
Air pump; replacing.......640
Throttle; replacing.......642
Burner function; checking.......644
Burner; replacing.......650
DPF (Diesel particulate filter) bracket; replacing.......654
NOx sensor; replacing.......659
Exhaust aftertreatment system T-junction; replacing.......661
DOC (Diesel oxidation catalyst); replacing.......663
Turbocharger; description.......666
Turbocharger; removing.......669
Turbocharger; installing.......674
Turbocharger; tightening torques.......678
Wastegate; checking.......681
Preheating coil; replacing.......683
Preheating; Specifications.......685
Charge air cooler; replacing.......686
26 - COOLING SYSTEM.......694
Cooling system; description.......695
Cooling system; specifications.......699
Carbon dioxide in coolant system; checking.......700
Cooling system; component location.......706
Cooling system pressure; checking.......708
Radiator; removing.......710
Radiator; installing.......719
Coolant pump; replacing.......726
Thermostat; replacing.......730
Thermostat; specifications.......734
Cooling fan; component location.......736
Cooling fan; description.......739
Reversible cooling fan; description.......743
Cooling fan motor; description.......747
Cooling fan; tightening torques.......749
Temperature limits for cooling fan speed; specifications.......751
Cooling fan rpm; specifications.......752
Fan control valve; seal replacing.......755
Drive belts; check.......758
27 - ENGINE CONTROL.......759
ECO - accelerator pedal.......760
29 - MISCELLANEOUS.......762
Exhaust Gas Recirculation (EGR); description.......763
Exhaust gas recirculation (EGR); component location.......768
EGR system; tightening torques.......770
EGR reed valve; replacing.......773
EGR cooler; replacing.......777
EGR temperature sensor; replacing.......785
EGR pressure sensor; replacing.......787
EGR valve; replacing.......790
EGR actuator; replacing.......792
EGR venturi tube; replacing.......795
EGR reed valve; inspecting.......797
EGR system function; checking.......801
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......804
30 - GENERAL.......805
Electrical system; work instructions.......811
Electrical system; description.......813
Software; description.......815
Electronic control system; description.......816
Communication with data buses.......825
VCADS Pro; Operations.......827
Electrical system; specifications.......829
Software parameters; description.......830