Volvo L120F Wheel Loader Workshop Service Repair Manual with Electrical Wiring Diagrams PDF - MVLVCOL120F.zip

Full service and repair documentation, complete with Electrical Wiring Diagrams, covering the Volvo L120F Wheel Loader—packed with every technical detail needed to service, troubleshoot, fix, and rebuild the machine just as professional technicians would.

The Volvo Construction Equipment L120F 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 L120F Wheel Loaders Service Repair Manual.pdf

PRODUCT DETAILS:

Total Pages: 2,571 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

03 - SPECIFICATIONS........4

Tightening torques........7

Oil sump; tightening torque ........18

Lubrication system; specifications........20

Fuel system; tightening torques........21

Thermostat; specifications ........23

Engine; specifications _........24

Speed sensor; specifications........25

Valve system specifications_........26

Engine; capacities ........27

Fuel system; specifications........28

Fuel tank; volume........29

Fuel feed pump; specifications........30

Thermostat; specifications........31

Cooling system; volume........32

Reversible cooling fan; tightening torques........33

Temperature limits for cooling fan speed; specifications........34

Cooling fan rpm; specifications_........35

Engine; specifications_........36

Speed sensor; tightening torque........38

Turbocharger; tightening torques........39

Battery; specifications........40

Battery; weight........41

Electrical system; specifications........42

Preheating; specifications........43

Alternator 080 A; specification........44

Front and rear axles; tightening torque........45

Front and rear axles; specifications_{002-12-13}........46

Front and rear axles; specifications_{002-11-50}........47

Front and rear axles; volume........48

Hydraulic transmission; volume_{002-10-49}........49

Hydraulic transmission; volume_{002-10-26}........50

Hydraulic transmission; specifications........51

Hydraulic transmission; tightening torques_{002-09-16}........53

Hydraulic transmission; tightening torques_{002-08-52}........54

Propeller shaft; tightening torque........55

Parking brake; specifications_{002-07-52}........56

Parking brake; specifications_{002-07-29}........57

Brake valve; tightening torques........58

Wheel brake; tightening torques........59

Wheel brake; specification........60

Brake system; specifications........61

Brake accumulator; specifications........62

Steering cylinder; tightening torque........63

Steering; specifications........64

Secondary steering pump; specifications........65

Control valve; lever steering (CDC); specifications........66

Lever steering (CDC); specifications........67

Rear axle mounting; volume........68

Frame joint; tightening torques........69

Frame; tightening torque........70

Wheels; specifications........71

Wheel; tightening torque........72

Cab; tightening torque........73

Air conditioning; refrigerant; weight_{002-00-38}........74

Air conditioning; refrigerant; weight_{002-00-14}........75

Air conditioning; tightening torques........76

Hydraulic system; volume........77

Control valve; specifications........78

Hydraulic pump (P001); specifications........79

Hydraulic pump (P002); specifications........80

Hydraulic pump (P003); specifications........81

Servo system; specifications........82

Boom Suspension System; specifications........83

Cooling fan rpm; specifications........84

Boom Suspension System; tightening torques........85

003rd_4th hydraulic function; specifications........86

Lift cylinder; tightening torques........87

Tilt cylinder; tightening torques........89

Conversion tables ........91

Hydraulic connections; tightening torques........95

Conversion tables........98

Engine; specifications ........102

07 - STANDARD TIME........104

Operation numbers for additional work........105

08 - TOOL........107

Infrared Thermometer........108

E-2017........112

E-2015........113

E-2001........115

E-2000........117

E 1708; Checking point........119

E1706........121

09 - MISCELLANEOUS........122

Basic checks........123

1 - STANDARD PARTS; SERVICE........125

16 - LUBRICANT; FUEL; OTHER FLUID........126

Recommended lubricants; oils........127

Coolant........129

Alternative fuels........134

17 - SERVICE........137

Working on the electrical system of the machine........139

Repairing hydraulic system........140

Cleanliness; brake and hydraulic systems........141

Electric welding ........142

Charging of batteries........144

Steering system working pressure; checking and adjusting ........145

Transmission oil pressure; checking_{01-39-57}........148

Transmission oil pressure; checking_{01-39-30}........153

Hydraulic pump; max working pressure; checking and adjusting ........158

Maintenance service; first 1000 hours_{01-35-41}........160

Maintenance service; first 1000 hours_{01-35-06}........170

Maintenance service; every 4000 hours_{01-34-10}........180

Maintenance service; every 4000 hours_{01-33-17}........210

Maintenance service; every 4000 hours_{01-32-19}........240

Service position 1_{01-30-33}........270

Brake discs; measuring wear........272

Wheel brake; specification_{01-29-23}........274

Boom suspension accumulator; checking and adjusting........275

Hydraulic pump P1 and P2; checking........279

Maintenance service; daily........281

Maintenance service; every 50 hours........283

Maintenance service; every 250 hours........287

Maintenance service; every 500 hours........294

Maintenance service; every 1000 hours_{01-24-41}........309

Maintenance service; every 1000 hours_{01-24-00}........327

Maintenance service; every 2000 hours_{01-23-05}........345

Maintenance service; every 2000 hours_{01-22-16}........373

Maintenance service; every 2000 hours_{01-21-24}........401

Maintenance service; every 6000 hours........429

Hydraulic oil level; checking........431

Hydraulic oil; changing........432

Hydraulic oil return filter; replacing_{01-18-52}........434

Hydraulic oil return filter; replacing_{01-18-25}........436

Engine oil level; checking........437

Engine oil filter; replacing........438

Hydraulic pump; max working pressure; checking and adjusting........440

Transmission oil pressure; checking_{01-16-12}........442

Transmission oil pressure; checking_{01-15-37}........447

Steering system working pressure; checking and adjusting........452

Parking brake; manually releasing_{01-14-15}........455

Parking brake; manually releasing_{01-13-48}........457

Towing........460

Electric welding........462

19 - GENERAL........463

CE-marking; EMC-directive........464

Safety concerns everybody!_{01-10-16}........468

Safety concerns everybody!_{01-09-52}........472

Checking function........474

Safety when handling the machine........475

Safety rules when servicing........480

Service position 2_{01-07-44}........483

Service position 1_{01-07-16}........485

Working under raised boom........487

Fire prevention measures........489

Some simple rules regarding tyre handling........493

Safety when lifting and supporting complete machine........495

Safety when working with batteries........499

Starting with booster batteries........502

Safety when handling oils and fuel........504

Safety when handling accumulators........506

Safety when working on hydraulic systems........508

Safety when using lifting equipment........511

Checklist after a fire or heat exposure........513

Health hazards with paint; plastics and rubber........516

Waste handling........519

Environmentally safe handling........523

Environmentally hazardous fluids........526

Safety when working with air conditioning refrigerant........529

Working in environmentally contaminated areas........532

Decontamination........535

2 - ENGINE WITH MOUNTING AND EQUIPMENT........539

20 - GENERAL........540

Engine; description........541

E-ECU MID 128 pre-programmed; replacing........549

E-ECU MID 128 non-programmed; replacing........551

21 - ENGINE........553

Engine; capacities........554

Cylinder compression; VCADS Pro........555

Stall speed; VCADS Pro........556

Stall speed; checking........557

Idle; VCADS Pro........559

Engine rotation speed sensor; replacing........560

Engine; removing_{12-51-35}........562

Engine; removing_{12-51-07}........573

VCADS Pro; central systems updating; replace component........584

VCADS Pro; MID 128; programming E-ECU........585

Engine; installing_{12-49-39}........586

Engine; installing_{12-49-10}........596

Engine; specifications........607

Cylinder compression; testing_{12-48-06}........609

Valve system specifications........614

Valve system specifications_{12-46-36}........615

Valves; adjusting_{12-46-12}........616

Internal Exhaust Gas Recirculation (IEGR); description........624

Crankshaft seal; front; changing........630

Oil sump; tightening torque........637

22 - LUBRICATING SYSTEM........640

Lubricating system; description........641

Lubrication system; specifications........645

Lubrication oil pressure; checking with pressure gauge........646

23 - FUEL SYSTEM........648

Fuel system; description........649

Fuel system; tightening torques........651

Instructions for working with electronic fuel injection........653

Fuel system; bleeding........656

Carbon dioxide in fuel system; checking........658

Fuel feed pump; specifications........664

Fuel feed pump; description........665

Fuel filter; description........666

Feed pump pressure; checking........668

Fuel filter; checking........670

Fuel tank; volume........672

Fuel tank; removing........673

Fuel tank; installing........677

Fuel system; specifications........681

Injectors; description........682

Injectors; replacing_{10-40-19}........685

Injectors; replacing_{10-39-26}........687

High pressure fuel pump; checking........690

Fuel rail; description........694

Cylinder compression; VCADS Pro_{10-34-33}........696

Fuel rail pressure sensor; replacing_{10-34-05}........697

High pressure fuel pump; replacing........699

Fuel control valve (FCV); description........707

Fuel control valve (FCV); checking........709

Fuel control valve (FCV); replacing........713

Pressure relief valve (PRV); inspecting........716

High pressure fuel pump; description........719

Pressure relief valve (PRV); replacing........721

25 - INLET & EXHAUST SYSTEM........724

Intake and exhaust system; description_{05-39-27}........725

Intake and exhaust system; description_{05-38-45}........728

Turbocharger; description........731

Turbocharger; inspecting........733

Air cleaner; description........735

Preheating; description........737

Intercooler; description........739

26 - COOLING SYSTEM........740

Cooling system; description........741

Carbon dioxide in coolant system; checking........744

Cooling system; volume........750

Radiator; removing........751

Radiator; installing........757

Thermostat; specifications........762

Cooling fan; component location........763

Cooling fan; description........765

Reversible cooling fan; description........772

Cooling fan motor; description........776

Hydraulic pump (P003); specifications........778

Cooling fan rpm; specifications........779

Temperature limits for cooling fan speed; specifications........780

Reversible cooling fan; tightening torques ........781

Cooling fan hydraulics; function check........782

Pump 003 (P3) standby pressure; checking and adjusting (LS-line removed)........783

Pump 003 (P3); max pressure and fan speed; checking and adjusting........786

Cooling fan motor; replacing........790

Fan control valve; removing........798

Fan control valve; seal replacing........800

Fan control valve; installing........802

Reversible cooling fan; tightening torques........804

27 - ENGINE CONTROL........805

Accelerator Pedal_{05-06-56}........806

Accelerator Pedal_{05-06-36}........808

Hand Throttle........809

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........811

30 - GENERAL........812

Electrical system; work instructions........818

Electrical system; description........820

Software; description........822

Electronic control system; description........823

Communication with data buses ........825

VCADS Pro; Operations........827

Electrical system; specifications........829

Software parameters; description........830

General fault diagnosis information........845

Troubleshooting strategy........847

Collection of basic data........849

Information display; check ........852

SAE error codes; translation to error messages; general........854

Communication with data buses........857

Bus communication supervision........859

Conditions when checking........861

Lead and connector checks........864

Troubleshooting tools........869

Special tools for troubleshooting........871

VCADS Pro; Error codes........873

VCADS Pro service tool........876

CU6601; description and measuring........880

CU9901; description and measuring........885

E-ECU PID158; description and measuring........888

HE2501; description and measuring........890