Volvo L120C Wheel Loader Repair Service Manual

Table of Content L120C Service Information

• GENERAL
  • DESCRIPTION, COMPLETE MACHINE
    • General
  • SPECIFICATIONS
    • General
      • Volvo standard tightening torques
  • STANDARD TIME
    • General
  • TOOL
    • General

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
    • General
  • SERVICE
    • Emergency measures
      • Manual release of parking brake
      • Removing propeller shafts
    • Miscellaneous

• ENGINE WITH MOUNTING AND EQUIPMENT
  • GENERAL
    • General, engine installation and its function
  • ENGINE
    • General, common info about 211 – 218
    • Valve mechanism
  • LUBRICATING SYSTEM
    • General, common info about 221 – 224
      • Specifications, tightening torques
    • Oil pump; line
      • Oil pump, removing and installing
  • FUEL SYSTEM
    • General (common info about 233 – 238)
    • Fuel pump; filter; strainer
      • Feed pump, checking feed pressure
    • Fuel tank; fuel filling pump
      • Fuel tank, removing and installing
    • Injection pump; regulator; pump companion
      • Idling speed, checking and adjusting
    • Injector; delivery pipe
  • INLET SYSTEM; EXHAUST SYSTEM
    • Turbo charger
    • Air cleaner with connections; air pre-heater
    • Charge air cooler with connections
  • COOLING SYSTEM
    • General, common info about 261 – 269
    • Coolant pump; thermostat
      • Coolant pump for intercooler, reconditioning
      • Coolant pump for intercooler, removing and installing
      • Coolant pump, removing and installing
  • ENGINE CONTROL
    • Stop control
      • Stop solenoid, adjusting stroke
        (solenoid positioned on inside of the radiator “bow”)
      • Stop solenoid, adjusting stroke
        (Solenoid positioned on the engine)
      • Stop solenoid, fault-tracing tips
    • Cold start control

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • GENERAL
    • Comprehensive info, electrical system
      • Special instructions for working on the electrical system
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • Battery
      • Safety when working with batteries
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • General, common info about 321 – 322
    • Alternator inclusive drive
      • Alternator 100 A, checking and adjusting voltage
  • STARTING SYSTEM
    • Starter motor inclusive solenoid
  • LIGHTING
    • General, common info about 351 – 356
    • Lighting, front, including parking light and day running light
  • OTHER ELECTRICAL EQUIPMENT
    • Automatic control/blocking function, lacking a function group of its own
      • General description of the control unit (ECU)
      • Other electrical functions (controlled by the control unit)
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
      • Codes used in wiring diagrams
      • Explanations of wiring diagrams (lead and component marking)
      • Loud tone horn∗, seat with air suspension∗
      • Wiring diagram, circuit 16:1 — 16:8
      • Wiring diagram, circuit 17:1 — 17:5
      • Wiring diagram, circuit 18:1 — 18:8
    • Electrical distribution box; fuse box; junction box
      • Electrical distribution box
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
    • Sender, monitoring system
      • Air conditioning, pressure monitor, SE22, checking
      • Air conditioning, thermostat, SE21, checking
      • Axle oil temperature, SE84 and SE84, checking
      • Engine temperature, SE1, checking
      • Transmission oil temperature, SE11, checking
    • Warning/information unit, display unit
      • Contronic Service Display Unit

• POWER TRANSMISSION
  • GENERAL
    • General, common info about 410 – 436
  • CLUTCH; TORQUE CONVERTER
    • Clutch control, manual or fixed
    • Hydrodynamic coupling, torque converter
  • TRANSMISSION, HYDRAULIC CONTROL
    • General
      • Specifications, capacities (dm3 = litre)
    • Transmission, hydraulic control
      • Transmission, checking oil pressure
  • GEARBOX,
    • Distributing gearbox
      • Specifications, capacities (dm3 = litre)
  • FRONT AXLE; REAR AXLE
    • General, common info about 461 – 468
      • Rear axle suspension, measuring axial and radial clearance
      • The axial clearance of the rear axle bridge, adjusting
      • Wear ring (differential carrier assembly), replacing
    • Front axle
      • Specifications, capacities (dm3 = litre)
    • Rear axle 1
      • Specifications, capacities (dm3 = litre)
    • Differential lock, with control

• BRAKE
  • GENERAL
    • Comprehensive info about brakes
  • WHEEL BRAKE
    • General, common info about 511 – 519
      • Brake discs, checking wear (with built-in wear indicator)
      • Brake discs, checking wear (without built-in wear indicator)
  • HYDRAULIC BRAKE SYSTEM
    • General, common info about 520 – 522
      • Checking function
      • Foot brake pedal, adjusting angle and pedal free travel
      • Pressure in circuit, checking and adjusting
    • Brake valve
      • Foot brake valve (removed), reconditioning
    • Brake accumulator; hydraulic pump
      • Accumulator, checking (removed)
  • PARKING BRAKE
    • General, common info about 551 – 554
      • Parking brake (mechanically operated), checking and adjusting
      • Parking brake, replacing discs

• STEERING
  • GENERAL
    • Comprehensive info, steering
  • STEERING
    • General, common info about 641 – 647
      • Hydraulic diagram, lever steering (CDC)∗ and secondary steering∗
    • Hydraulic equipment
      • Shift valve, reconditioning (removed)
      • Shift valve, description
      • Stand-by pressure and working pressure, checking and adjusting
      • Steering pump, reconditioning (removed)
      • Steering valve, reconditioning (removed)
    • Supplementary steering
  • LEVER STEERING
    • General
      • Lever steering, adjusting steering speed
      • Lever steering, checking and adjusting control valve
      • Steering lever CU3, checking input/output voltage

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • GENERAL
    • Comprehensive info about frame and track unit/wheels
  • FRAME
    • Frame, complete
    • Protection; belly plate; bumper
    • Counterweight
    • Specifications, tightening torques
  • FRAME LINK
    • Bearings
      • Frame joint, replacing bearings
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • Wheel

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • CAB, NAKED; CANOPY
    • General
  • TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
    • Glass; sealing moulding
      • Rear window, sealing
      • Windscreen side pane, replacing and sealing
      • Windscreen, replacing and sealing
      • Windscreen, sealing
  • AIR CONDITIONING UNIT
    • General, common info about 872 – 877
    • Air distribution incl. air intake with filter
    • Cooling unit
      • Air conditioning, performance test
      • Electrical system, air conditioning, description of function

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • Hydraulic diagrams, working hydraulics
    • Working hydraulics
      • Shock and anti-cavitation valve
    • Pump, working hydraulics
      • Working pressure, checking and adjusting
    • Servo hydraulic system
      • Pressure back-up for servo circuit, accumulator checking
      • Servo pressure, checking and adjusting
        (machine without separate attachment locking)
      • Servo pressure, checking and adjusting
        (machine with separate attachment locking)
      • Servo pressure, checking at spool in control valve
      • Servo valve, description of function
      • Servo valve, operating controls, adjusting
    • Other hydraulic equipment
      • 4th hydraulic function, description
      • Accumulator for Boom Suspension System, releasing pressure
      • Accumulator, Boom Suspension System, reconditioning
      • Accumulator, precharging pressure, checking and adjusting
      • Boom Suspension System, checking
      • Pressure-reducing valves R1 and R2,
        closing pressure, checking
      • Releasing the hydraulic oil pressure in the accumulator
  • UNIT, LOAD HANDLING
    • Lifting frame work with mounting and link arm system
      • Boom kick-out and bucket positioner, adjusting
      • Lifting arm, replacing bearings at lower bucket or attachment mounting
      • Lifting cylinder, changing seals in machine
      • Lifting cylinder, replacing bushings (removed)
      • Lifting/tilting cylinder, (principle diagram)
      • Shock valve, lifting function, checking and adjusting
      • Shock valve, tilting function, checking and adjusting
      • Tilting cylinder, changing seals in machine
      • Tilting cylinder, replacing bearings (removed)