Volvo L120H Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L120H Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L120H Wheel Loaders workshop service repair manual includes:
* 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
CU9901; description and measuring_{08-14-30}......954
FX1005; description and measuring......957
FX1006; description and measuring......959
FX1007; description and measuring......962
FX1008; description and measuring......965
FX1009; description and measuring......968
FX1024; description and measuring......971
FX1025; description and measuring......974
FX1074; description and measuring......977
FX1079; description and measuring......980
FX1089; description and measuring......983
HE2501; description and measuring......987
HE2511; description and measuring......989
HE2512; description and measuring......991
HE2513; description and measuring......993
Instrument Cluster (IC); description and measuring_{08-04-12}......995
Instrument Cluster (IC); description and measuring_{08-03-44}......998
Load Assist; sensor network; description and measuring_{08-03-01}......1001
Load Assist; sensor network; description and measuring_{08-02-36}......1004
MA2301-MA2306; description and measuring......1007
MA2517; description and measuring......1013
MA2519; description and measuring......1015
MA2601; description and measuring......1017
MA2602; description and measuring......1019
MA4603; description and measuring_{02-55-22}......1021
MA4603; description and measuring_{02-50-30}......1024
MA5501; description and measuring......1027
MA5503; description and measuring......1030
MA8701; description and measuring......1032
MA9103; description and measuring......1034
MA9104; description and measuring......1036
MA9106; description and measuring_{02-16-02}......1038
MA9106; description and measuring_{02-12-53}......1040
MA9114; description and measuring......1042
MA9127; description and measuring_{02-03-35}......1044
MA9127; description and measuring_{01-59-41}......1046
MA9127; description and measuring_{01-55-52}......1048
MO2503; description and measuring......1050
MO2505; description and measuring......1052
MO3301; description and measuring_{01-39-52}......1054
MO3301; description and measuring_{01-37-21}......1056
MO3612; description and measuring......1058
MO3613; description and measuring......1060
MO6402; description and measuring_{01-31-10}......1062
MO6402; description and measuring_{01-27-57}......1064
MO8703; description and measuring......1066
MO8707; description and measuring......1069
MO8711; description and measuring_{01-10-37}......1072
MO8711; description and measuring_{01-07-31}......1075
Power supply; ACM (Aftertreatment Control Module); description and measuring......1078
Power supply CCM; description and measuring......1081
Power supply ECM; description and measuring......1083
Power supply GPMECU 1; description and measuring......1085
Power supply GPMECU 2; description and measuring......1088
Power supply GPMECU 3; description and measuring......1090
Power supply HMICU; description and measuring......1092
Power supply SID; description and measuring......1094
Power supply W-ECU; description and measuring......1097
PWM2303; description and measuring......1100
PWM2602; description and measuring......1102
PWM4203; description and measuring......1104
PWM4213 - PWM4218; description and measuring_{11-50-30}......1106
PWM4213 - PWM4218; description and measuring_{11-37-28}......1111
PWM5202; description and measuring......1116
PWM6601; description and measuring......1119
PWM6602; description and measuring......1122
PWM9101; description and measuring......1125
PWM9102; description and measuring......1127
PWM9103; description and measuring......1129
PWM9104; description and measuring_{10-54-35}......1131
PWM9104; description and measuring_{10-51-40}......1133
PWM9105; description and measuring_{10-48-11}......1135
PWM9105; description and measuring_{10-25-48}......1137
PWM9106; description and measuring_{10-22-24}......1139
PWM9106; description and measuring_{10-19-23}......1141
PWM9107; description and measuring_{10-15-55}......1143
PWM9107; description and measuring_{10-12-55}......1145
PWM9108; description and measuring_{10-09-25}......1147
PWM9108; description and measuring_{10-06-23}......1149
R2701; description and measuring_{10-03-02}......1151
R2701; description and measuring_{09-59-06}......1154
RE02; description and measuring......1157
RE03; description and measuring......1160
RE04; description and measuring......1162
RE07; description and measuring......1164
RE08; description and measuring......1166
RE09; description and measuring......1168
RE10; description and measuring......1170
RE11; description and measuring......1173
RE12; description and measuring......1175
RE13; description and measuring......1177
RE14; description and measuring......1179
RE15; description and measuring......1181
RE16; description and measuring_{08-14-59}......1183
RE16; description and measuring_{08-13-36}......1185
RE17; description and measuring_{08-12-01}......1187
RE17; description and measuring_{08-10-38}......1189
RE18; description and measuring_{08-08-57}......1191
RE18; description and measuring_{08-07-07}......1193
RE2301; description and measuring......1196
RE2501; description and measuring......1198
RE2502; description and measuring......1200
RE3102; description and measuring......1202
RE3504; description and measuring......1204
RE3507; description and measuring......1207
RE3524; description and measuring......1209
RE3531; description and measuring......1211
RE3610; description and measuring......1214
RE3705; description and measuring......1216
RE5502; description and measuring......1219
RE6401; description and measuring_{07-06-58}......1221
RE6401; description and measuring_{07-04-54}......1223
RE8712; description and measuring_{07-02-26}......1225
RE8712; description and measuring_{06-59-33}......1228
RF1; description and measuring......1231
SAE J1939-1 SubNet 1; description and measuring......1233
SE2203; description and measuring......1237
SE2301; description and measuring......1239
SE2303; description and measuring......1241
SE2309; description and measuring......1244
SE2511; description and measuring......1246
SE2512; description and measuring......1248
SE2513; description and measuring_{06-12-58}......1250
SE2513; description and measuring_{06-10-22}......1252
SE2515; description and measuring......1254
SE2516; description and measuring......1256
SE2519; description and measuring_{05-57-32}......1258
SE2519; description and measuring_{05-54-34}......1260
SE2521; description and measuring......1262
SE2522; description and measuring......1264
SE2533; description and measuring_{05-41-40}......1266
SE2533; description and measuring_{05-39-07}......1268
SE2543; description and measuring......1270
SE2544; description and measuring......1273
SE2603; description and measuring......1275
SE2604; description and measuring......1277
SE2606; description and measuring......1279
SE2701; description and measuring......1281
SE2702; description and measuring_{05-10-32}......1283
SE2702; description and measuring_{05-06-55}......1286
SE2703; description and measuring......1289
SE2704; description and measuring......1291
SE4202; description and measuring......1293
SE4203; description and measuring......1295
SE4209; description and measuring......1297
SE4213; description and measuring......1299
SE4218; description and measuring......1301
SE4219; description and measuring......1303
SE4226; description and measuring......1305
SE4227; description and measuring......1307
SE4307; description and measuring......1310
SE4312; description and measuring......1312
SE4609; description and measuring......1314
SE5201; description and measuring......1316
SE5203; description and measuring......1319
SE5222; description and measuring......1321
SE5223; description and measuring......1323
SE5501; description and measuring......1325
SE6404; description and measuring......1328
SE6407; description and measuring......1330
SE6411; description and measuring......1332
SE6601; description and measuring_{03-26-46}......1335
SE6601; description and measuring_{03-17-41}......1341
SE8301; description and measuring......1346
SE8702; description and measuring......1349
SE8705; description and measuring_{03-01-00}......1352
SE8705; description and measuring_{02-58-35}......1355
SE8706; description and measuring......1358
SE8708; description and measuring......1361
SE8709; description and measuring......1364
SE9116; description and measuring......1367
SE9117; description and measuring......1370
SE9119; description and measuring......1373
SE9147; description and measuring......1376
SE9148; description and measuring......1379
SE9482; description and measuring_{02-17-31}......1382
SE9482; description and measuring_{02-14-51}......1385
SE9483; description and measuring_{02-11-54}......1388
SE9483; description and measuring_{02-09-15}......1391
SE9484; description and measuring_{02-06-14}......1394
SE9484; description and measuring_{02-03-36}......1397
SE9485; description and measuring_{02-00-36}......1400
SE9485; description and measuring_{01-57-50}......1403
SE9485; description and measuring_{01-55-11}......1406
SE9486; description and measuring_{01-52-10}......1409
SE9486; description and measuring_{01-49-33}......1412
SE9486; description and measuring_{01-46-59}......1415
SE9901; description and measuring......1418
SW2506; description and measuring......1420
SW3630; description and measuring......1423
SW3701; description and measuring......1425
SW3801; description and measuring......1428
SW4205_SW4206; description and measuring_{01-24-29}......1430
SW4205_SW4206; description and measuring_{01-21-54}......1433
SW4208; description and measuring......1436
SW4209; description and measuring......1438
SW4210; description and measuring......1440
SW4211; description and measuring_{01-08-18}......1442
SW4211; description and measuring_{01-06-33}......1445
SW4217; description and measuring......1448
SW4219; description and measuring_{01-01-23}......1450
SW4219; description and measuring_{12-59-40}......1453
SW4220; description and measuring......1456
SW4222; description and measuring......1458
SW5501; description and measuring......1460
SW8701; description and measuring......1463
SW9143; description and measuring_{12-46-09}......1465
SW9143; description and measuring_{12-42-56}......1468
SW9144; description and measuring_{12-39-37}......1471
SW9144; description and measuring_{12-38-06}......1473
SW9144; description and measuring_{12-36-39}......1475
SW9148; description and measuring_{12-34-54}......1477
SW9148; description and measuring_{12-33-05}......1480
SW9149; description and measuring_{12-31-11}......1483
SW9149; description and measuring_{12-30-06}......1485
SW9174; description and measuring......1487
SW9175; description and measuring_{12-25-56}......1489
SW9175; description and measuring_{12-24-01}......1491
31 - BATTERY......1494
System voltage......1495
Key feed......1497
Battery; description......1499
Battery; weight......1500
Battery; specifications......1501
Battery condition; checking......1502
Battery; charging......1505
Batteries; replacing......1507
32 - ALTERNATOR; CHARGE REGULATOR......1509
Alternator 80 A; specification......1510
Alternator; description......1511
Alternator 80 A; description......1515
33 - STARTING SYSTEM......1516
Starter motor; specifications......1517
Starter motor; description......1518
Starter motor; tightening torques......1520
Booting sequence......1523
Starter motor; replacing......1525
Preheating; specifications......1527
Preheating; description......1528
Starter lock; replacing......1530
35 - LIGHTING......1532
Lighting; specifications......1533
36 - OTHER ELECTRICAL EQUIPMENT......1534
Intermittent wiper and washer......1535
Connectors; position......1541
Connectors; overview......1552
GPMECU1 non-programmed; replacing......1556
GPMECU1 pre-programmed; replacing......1559
GPMECU2 non-programmed; replacing......1562
GPMECU2 pre-programmed; replacing......1565
GPMECU3 non-programmed; replacing......1568
GPMECU3 pre-programmed; replacing......1571
HMICU non-programmed; replacing......1574
HMICU pre-programmed; replacing......1577
Hood opening......1580
37 - CABLE; FUSE; RELAY......1582
Electrical symbols and designations......1588
Cable and component designations......1591
Cable and component marking explanations......1593
Components list......1596
ACM; I_O list......1608
CCM; I_O list......1610
ECM (Engine Control Module); I_O list......1613
GPMECU1; I_O list......1617
GPMECU2; I_O list......1621
GPMECU3; I_O list......1625
HMICU; I_O list......1629
W-ECU; I_O list......1631
Table of contents; wiring diagrams......1632
Wiring diagram - CDC......1635
Wiring diagram - Start......1639
Wiring diagram - Aftertreatment_{11-39-41}......1642
Wiring diagram - Aftertreatment_{11-38-37}......1647
Wiring diagram - Brake......1652
Wiring diagram - BSS......1656
Wiring diagram - Electrically controlled battery disconnector - Key operated; with emergency stop......1659
Wiring diagram - Electrically controlled battery disconnector - Manual; with emergency stop......1663
Wiring diagram - Electrically controlled battery disconnector - Manual; without emergency stop......1667
Wiring diagram - Gear......1671
Wiring diagram WD201......1675
Wiring diagram WD202_{11-30-11}......1679
Wiring diagram WD202_{11-29-33}......1682
Wiring diagram WD260......1685
Wiring diagram WD261......1688
Wiring diagram WD262......1691
Wiring diagram WD263......1695
Wiring diagram WD264_{11-25-11}......1698
Wiring diagram WD264_{11-24-42}......1702
Wiring diagram WD265......1706
Wiring diagram WD266......1709
Wiring diagram WD268......1712
Wiring diagram WD269......1715
Wiring diagram WD270......1719
Wiring diagram WD301_{11-20-35}......1722
Wiring diagram WD301_{11-20-06}......1726
Wiring diagram WD301_{11-19-38}......1730
Wiring diagram WD302_{11-18-52}......1734
Wiring diagram WD302_{11-18-24}......1738
Wiring diagram WD303_{11-17-47}......1742
Wiring diagram WD303_{11-17-24}......1745
Wiring diagram WD304_{11-16-35}......1748
Wiring diagram WD304_{11-16-10}......1752
Wiring diagram WD304_{11-15-45}......1757
Wiring diagram WD305......1761
Wiring diagram WD306_{11-14-33}......1764
Wiring diagram WD306_{11-14-05}......1767
Wiring diagram WD306_{11-13-38}......1770
Wiring diagram WD320_{11-13-00}......1773
Wiring diagram WD320_{11-12-37}......1776
Wiring diagram WD321_{11-12-01}......1779
Wiring diagram WD321_{11-11-38}......1782
Wiring diagram WD322_{11-11-02}......1785
Wiring diagram WD322_{11-10-38}......1788
Wiring diagram WD322_{11-10-13}......1792
Wiring diagram WD324_{11-09-34}......1795
Wiring diagram WD324_{11-09-07}......1799
Wiring diagram WD324_{11-08-39}......1803
Wiring diagram WD325_{11-08-01}......1807
Wiring diagram WD325_{11-07-36}......1811
Wiring diagram WD326......1814
Wiring diagram WD327......1817
Wiring diagram WD330_{11-05-35}......1821
Wiring diagram WD330_{11-05-06}......1826
Wiring diagram WD331_{11-04-21}......1830
Wiring diagram WD331_{11-03-54}......1834
Wiring diagram WD333_{11-03-16}......1838
Wiring diagram WD333_{11-02-48}......1842
Wiring diagram WD334_{11-02-09}......1846
Wiring diagram WD334_{11-01-44}......1850
Wiring diagram WD335_{11-00-54}......1854
Wiring diagram WD335_{11-00-30}......1857
Wiring diagram WD337......1860
Wiring diagram WD350_{10-59-17}......1864
Wiring diagram WD350_{10-58-53}......1867
Wiring diagram WD351......1870
Wiring diagram WD352_{10-57-43}......1873
Wiring diagram WD352_{10-57-20}......1876
Wiring diagram WD360_{10-56-46}......1879
Wiring diagram WD360_{10-56-22}......1882
Wiring diagram WD360_{10-55-57}......1885
Wiring diagram WD361......1888
Wiring diagram WD362_{10-54-49}......1891
Wiring diagram WD362_{10-54-26}......1894
Wiring diagram WD363......1897
Wiring diagram WD371_{10-53-17}......1900
Wiring diagram WD371_{10-52-53}......1903
Wiring diagram WD372......1906
Wiring diagram WD373_{10-51-43}......1909
Wiring diagram WD373_{10-51-20}......1912
Wiring diagram WD373_{10-50-57}......1915
Wiring diagram WD374_{10-50-22}......1918
Wiring diagram WD374_{10-49-58}......1921
Wiring diagram WD375......1924
Wiring diagram WD376......1927
Wiring diagram WD401_{10-48-09}......1930
Wiring diagram WD401_{10-47-45}......1933
Wiring diagram WD402......1936
Wiring diagram WD403_{10-46-21}......1939
Wiring diagram WD403_{10-45-52}......1942
Wiring diagram WD404......1945
Wiring diagram WD405_{10-44-41}......1948
Wiring diagram WD405_{10-44-14}......1952
Wiring diagram WD406_{10-43-35}......1956
Wiring diagram WD406_{10-43-10}......1959
Wiring diagram WD501......1962
Wiring diagram WD601_{10-41-50}......1966
Wiring diagram WD601_{10-41-25}......1969
Wiring diagram WD602_{10-40-50}......1972
Wiring diagram WD602_{10-40-26}......1975
Wiring diagram WD604_{10-39-48}......1978
Wiring diagram WD604_{10-39-24}......1981
Wiring diagram WD801_{10-38-48}......1984
Wiring diagram WD801_{10-38-20}......1988
Wiring diagram WD802_{10-37-44}......1992
Wiring diagram WD802_{10-37-20}......1997
Wiring diagram WD804......2001
Wiring diagram WD805......2005
Wiring diagram WD806_{10-35-31}......2009
Wiring diagram WD806_{10-35-05}......2013
Wiring diagram WD807......2017
Wiring diagram WD808......2021
Wiring diagram WD831......2025
Wiring diagram WD901_{10-32-26}......2028
Wiring diagram WD901_{10-32-02}......2031
Wiring diagram WD902......2034
Wiring diagram WD903_{10-30-47}......2037
Wiring diagram WD903_{10-30-23}......2041
Wiring diagram WD904_{10-29-43}......2045
Wiring diagram WD904_{10-29-16}......2048
Wiring diagram WD904_{10-28-48}......2051
Wiring diagram WD908_{10-28-07}......2054
Wiring diagram WD908_{10-27-44}......2057
Wiring diagram WD909_{10-27-08}......2060
Wiring diagram WD909_{10-26-41}......2064
Wiring diagram WD910......2068
Wiring diagram WD911_{10-25-30}......2071
Wiring diagram WD911_{10-25-07}......2074
Wiring diagram WD912......2077
Wiring diagram WD913_{10-24-03}......2080
Wiring diagram WD913_{10-23-39}......2084
Wiring diagram WD915_{10-23-00}......2088
Wiring diagram WD915_{10-22-37}......2091
Battery disconnect switch; description......2094
Electrical distribution box; description......2097
Chassis connection......2109
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......2111
Rear vision system......2112
Information display; general......2115
Information display; service mode......2119
Volvo Co-Pilot; description_{10-12-07}......2122
Volvo Co-Pilot; description_{10-11-44}......2126
Volvo Co-Pilot; component location......2128
Volvo Co-Pilot; specifications......2130
Volvo Co-Pilot; tightening torques......2132
Volvo Co-Pilot application; installing......2134
Volvo Co-Pilot; replacing......2139
Volvo Co-Pilot SIM card; installing_{10-08-42}......2141
Volvo Co-Pilot SIM card; installing_{10-08-19}......2148
USB tethering......2151
Volvo Co-Pilot Android software; updating online (OtA)_{10-07-05}......2158
Volvo Co-Pilot Android software; updating online (OtA)_{10-06-42}......2161
Volvo Co-Pilot; software updating......2163
Reverse warning system; description......2167
39 - MISCELLANEOUS......2171
CareTrack W-ECU; description......2172
W-ECU; replacing; non-programmed......2176
W-ECU; replacing; pre-programmed......2178
004 - POWER TRANSMISSION......2180
40 - GENERAL......2181
Drivetrain; component location_{10-01-14}......2182
Drivetrain; component location_{10-00-51}......2184
Tech Tool; operations_{10-00-16}......2187
Tech Tool; operations_{09-59-57}......2189
Error codes when calibrating-[5928]......2191
42 - TRANSMISSION; HYDRAULIC CONTROL......2197
Hydraulic diagram transmission - Image......2199
Transmission; component location_{09-58-57}......2201
Transmission; component location_{09-58-33}......2206
Transmission; component location_{09-58-10}......2210
Transmission; component location_{09-57-37}......2214
Transmission; component location_{09-57-14}......2219
Transmission; component location_{09-56-46}......2223
Transmission; specifications_{09-56-05}......2227
Transmission; specifications_{09-55-42}......2229
Transmission; specifications_{09-55-20}......2231
Transmission; specifications_{09-54-57}......2233
Hydraulic transmission; capacity_{09-54-23}......2235
Hydraulic transmission; capacity_{09-54-03}......2236
Transmission; tightening torques_{09-53-32}......2237
Transmission; tightening torques_{09-53-09}......2239
Transmission; tightening torques_{09-52-47}......2241
Hydraulic transmission; description_{09-52-06}......2243
Hydraulic transmission; description_{09-51-31}......2255
Hydraulic transmission; description_{09-50-54}......2266
Hydraulic transmission; description_{09-50-23}......2276
Hydraulic transmission calibration; description......2286
Hydraulic transmission; warming up......2290
Transmission; specifications_{09-46-56}......2291
Transmission; specifications_{09-46-32}......2293
Transmission; specifications_{09-46-08}......2295
Transmission; specifications_{09-45-44}......2297
Transmission; removing_{09-45-08}......2299
Transmission; removing_{09-44-45}......2310
Transmission; installing_{09-44-04}......2322
Transmission; installing_{09-43-41}......2331
Hydraulic diagram transmission_{09-42-57}......2340
Hydraulic diagram transmission_{09-42-34}......2343
Lock up valve; replacing......2346
Transmission oil pressure; checking_{09-41-32}......2348
Transmission oil pressure; checking_{09-41-10}......2353
Transmission oil pressure; checking_{09-40-47}......2358
Transmission oil pressure; checking_{09-40-24}......2362
Gear selector valve; replacing one solenoid_{09-39-50}......2366
Gear selector valve; replacing one solenoid_{09-39-27}......2370
Seal for front output shaft; replacing_{09-38-53}......2373
Seal for front output shaft; replacing_{09-38-30}......2376
Seal for rear output shaft; replacing......2380
Transmission; function check_{09-37-19}......2383
Transmission; function check_{09-36-57}......2385
Transmission; calibration......2387
45 - PROPELLER SHAFT......2389
Propeller shaft; tightening torque......2390
Propeller shaft; component description......2391
46 - FRONT AXLE; REAR AXLE......2393
Drive axles; description......2394
Front and rear axles; tightening torque......2398
Front and rear axles; specifications......2399
Front axle; component description......2400
Rear axle; component description......2402
Rear axle mounting; component description......2404
Front and rear axles; volume......2407
Automatic differential brake; Limited Slip; description......2408
Rear axle mounting; volume......2411
Hub seal; replacing......2412
Hub reduction; removing-......2430
Hub reduction; installing-......2433
Axle; removing......2435
Axle suspension bushes and seals; replacing......2439
Axle suspension; tightening torque......2450
Axle; installing......2451
Hub reduction; removing......2455
Hub reduction; installing......2458
Differential lock; description_{09-24-17}......2460
Differential lock; description_{09-23-55}......2464
Differential lock; adjusting......2468
Differential lock; function check......2473
49 - MISCELLANEOUS......2475
Oil cooler; component location......2476
Heat exchanger; replacing......2477
005 - BRAKE......2482
50 - GENERAL......2483
Tech Tool; operations......2484
51 - WHEEL BRAKE......2485
Wheel brake; specification......2486
Brake discs; measuring wear......2487
Brake discs; replacing......2490
Brake disc; replacing......2496
Brake piston seals; replacing......2502
52 - HYDRAULIC BRAKE SYSTEM......2507
Brake system; component location......2508
Braking system; description_{06-58-46}......2511
Braking system; description_{06-58-22}......2518
Brake system; specifications......2528
Brake system circuit pressure; checking and adjusting......2529
Brake system; bleeding......2532
Brake system retardation function; checking......2534
Automatic brake function; checking......2536
Brake system charging; checking......2538
Axle oil cooler; component location......2543
Axle oil cooler; description......2545
Foot brake valve; description......2548
Automatic brake valve; description......2550
Brake accumulator; description......2552
Brake accumulator; specifications......2554
Accumulator (removed) charging pressure; checking......2555
Accumulator; removing......2557
Accumulator; installing......2559
Accumulators; checking in machine......2561
Accumulator; discarding......2563
55 - PARKING BRAKE......2566
Tightening torque ......2567
Parking brake assembly; removing ......2568
Parking brake; function description_{010-44-13}......2572
Parking brake; adjusting ......2579
Parking brake brake pads; replacing ......2582
Parking brake; disassembling ......2585
Parking brake; assembling ......2587
Parking brake; installing ......2590
Parking brake discs and seals; replacing ......2593
Parking brake; specifications_{06-50-32}......2599
Parking brake; specifications_{06-50-13}......2600
Tightening torque......2601
Parking brake; component location_{06-49-24}......2602
Parking brake; component location_{06-49-02}......2604
Parking brake; component description_{06-48-31}......2607
Parking brake; component description_{06-48-10}......2609
Parking brake assembly; removing......2611
Parking brake; function description_{06-47-12}......2615
Parking brake; function description_{06-46-49}......2621
Parking brake; adjusting......2628
Parking brake brake pads; replacing......2631
Parking brake; disassembling......2634
Parking brake; assembling......2636
Parking brake; installing......2639
Parking brake discs and seals; replacing......2642
Parking brake function; checking......2648
006 - STEERING......2649
60 - GENERAL......2650
Tech Tool; operations......2651
Steering system; component location_{09-20-34}......2652
Steering system; component location_{09-20-11}......2654
Steering system; description_{09-19-31}......2656
Steering system; description_{09-19-07}......2665
Steering system function; checking......2671
Lever steering CDC; tightening torques......2673
Comfort Drive Control (CDC); description_{09-00-37}......2675
Comfort Drive Control (CDC); description_{09-00-14}......2682
CDC valve; lever steering; description......2689
Lever steering (CDC); specifications......2692
Comfort Drive Control (CDC); component location......2693
Comfort drive control (CDC) angle sensor; changing......2695
Comfort Drive Control; servo pressure; checking......2699
Comfort Drive Control (CDC) joystick; changing......2701
Comfort drive control (CDC) solenoid valve; changing......2706
Lever steering (CDC) function; checking......2709
Calibration of Comfort Drive Control (CDC); function description......2712
Calibration of Comfort Drive Control (CDC); specification......2717
64 - STEERING......2719
Steering; specifications_{09-16-53}......2721
Steering; specifications_{09-16-34}......2722
Steering cylinder; description_{09-15-51}......2723
Steering cylinder; description_{09-15-28}......2725
Steering valve; description......2727
Steering cylinder; tightening torque_{09-14-28}......2729
Steering cylinder; tightening torque_{09-14-05}......2730
Shift valve; description-[1333]......2732
Steering system working pressure; checking and adjusting......2735
Left steering cylinder; removing_{09-12-37}......2738
Left steering cylinder; removing_{09-12-14}......2743
Right steering cylinder; removing_{09-11-40}......2747
Right steering cylinder; removing_{09-11-18}......2751
Steering cylinder removed; reconditioning excl replacing bearings_{09-10-44}......2755
Steering cylinder removed; reconditioning excl replacing bearings_{09-10-21}......2759
Left steering cylinder; installing_{09-09-47}......2763
Left steering cylinder; installing_{09-09-24}......2768
Right steering cylinder; installing_{09-08-50}......2774
Right steering cylinder; installing_{09-08-28}......2779
Steering accumulator; removing......2784
Steering accumulator; installing......2786
Accumulator; discarding-......2788
Steering accumulator removed; checking......2790
Secondary steering pump; specifications_{09-05-52}......2792
Secondary steering pump; specifications_{09-05-32}......2793
Secondary steering pump; specifications_{09-05-07}......2794
Secondary steering pump; specifications_{09-04-47}......2795
Secondary steering; component location......2796
Secondary steering; description_{09-03-43}......2798
Secondary steering; description_{09-03-21}......2802
Pressure monitor; description-......2806
Secondary steering pump working pressure; checking and adjusting......2808
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......2810
70 - GENERAL......2811
Frame; description......2812
71 - FRAME......2815
Counterweight; tightening torques......2816
Counterweight; weight......2817
74 - FRAME LINK......2819
Frame joint; tightening torques......2820
Frame joint; description......2821
Frame joint; replacing bearings......2823
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......2853
Wheel; tightening torque......2854
Rear wheel; removing......2855
Rear wheel; installing......2858
Front wheel; removing......2861
Front wheel; installing......2864
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......2867
80 - GENERAL......2868
Cab; description......2869
Air conditioning; tightening torques......2871
Tech Tool; operations......2872
82 - ENGINE HOOD; MUDGUARD; FOOT STEP......2873
Plastic hood; repairing......2874
Engine hood; raising and securing......2879
Actuator; replacing......2881
83 - DOORS; HATCH; COVER PLATE; (all)......2886
Electric door opener; description......2887
Electric door opener; control unit; replacing......2891
Electric door opener; locking motor; replacing......2893
Electric door opener; rotor switch; replacing......2895
Electric door opener; opening support motor; replacing......2897
Door lock cylinder; replacing_{08-36-46}......2899
Door lock cylinder; replacing_{08-36-23}......2907
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......2915
Windows; general......2916
Side window; replacing_{08-34-11}......2918
Windscreen; replacing_{08-33-41}......2928
Window pane; installing......2938
Windows; general; gluing......2943
85 - CAB INTERIOR; UPHOLSTERY......2946
Operator seat; tightening torques......2947
Operator's seat; securing......2952
Driver seat; component description_{08-29-22}......2954
Driver seat; component description_{08-28-59}......2957
Driver seat; component description_{08-28-37}......2960
Driver seat; component description_{08-28-14}......2963
87 - AIR CONDITIONING UNIT......2966
CCM; replacing......2967
Climate control system; description......2971
Climate unit; removing......2976
Climate unit; installing......2985
Pause heater; description......2992
Fan motor; replacing......2994
Air mix door actuator; replacing......2997
Heater core; replacing......3002
Heat control valve; replacing......3005
Air conditioning; tightening torques......3009
Air conditioning; specifications......3010
Air conditioning; refrigerant; weight......3012
Air conditioning; checking performance......3013
Cooling unit; leak detection......3015
Drying filter; replacing......3017
Condenser; replacing......3021
Compressor; replacing......3026
Evaporator; replacing......3031
Expansion valve; replacing......3039
Air conditioning; function description......3050
Air conditioning; component location......3053
Refrigerant; draining......3055
Refrigerant; filling incl vacuum pumping......3058
Troubleshooting; air conditioning unit (AC)......3062
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......3066
90 - GENERAL......3067
Hydraulic diagram; complete - Image......3068
Hydraulic diagram; basic machine - Image......3071
Explanations to hydraulic diagram......3074
Hydraulic components; cleanliness when handling......3083
Hydraulic diagram; complete_{08-10-27}......3086
Hydraulic diagram; complete_{08-10-04}......3089
Hydraulic diagram; complete_{08-09-39}......3093
Hydraulic diagram; basic machine_{08-09-05}......3096
Hydraulic diagram; basic machine_{08-08-42}......3099
Hydraulic diagram; basic machine_{08-08-20}......3102
Hydraulic system; volume......3105
Hydraulic system; bleeding......3106
Hydraulic system; warming up......3109
Tech Tool; operations......3111
Control valve; tightening torques......3114
3rd_4th hydraulic function; tightening torques......3116
Accumulator; discarding......3118
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......3121
Calibration of working hydraulics; specifications......3124
Error codes when calibrating......3127
Hydraulic oil tank; description......3133
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump......3135
Hydraulic connections; tightening torques......3137
Hydraulic couplings......3139
Pressure back-up valve; replacing......3143
Working hydraulic system; component location......3146
Working hydraulic system; description_{08-00-31}......3148
Working hydraulic system; description_{08-00-07}......3158
Control valve; description......3167
Central valve; description......3171
Control valve; specifications......3173
Back-up valve; checking and adjusting......3175
Shock valve lift function; checking......3177
Shock valve; tilt function; checking......3180
Lift; solenoid valve; changing......3183
Lower; solenoid valve; changing......3186
Tilt in; solenoid valve; changing......3189
Tilt out; solenoid valve; changing......3192
Lift_lower; angle sensor; changing_{07-54-48}......3195
Lift_lower; angle sensor; changing_{07-54-25}......3200
Tilt in_out; angle sensor; changing_{07-53-51}......3206
Tilt in_out; angle sensor; changing_{07-53-27}......3212
Tilt; checking......3220
Lift_lower function; checking......3222
Calibration of lift_ lower function; description......3226
Calibration of tilt in_out function; description......3231
Hydraulic pumps; description......3236
Hydraulic pump flow regulation; description......3238
Hydraulic pump (P1); specifications......3242
Hydraulic pump (P2); specifications......3243
Hydraulic pump (P3); specifications......3244
Function times; specifications......3245
Hydraulic pumps; tightening torques......3247
Hydraulic pump; standby pressure and working pressure; checking and adjusting......3248
LS (load sense) pressure; checking......3252
Hydraulic pump P1; removing......3255
Hydraulic pump P1; installing......3259
Hydraulic pump P2; removing......3262
Hydraulic pump P2; installing......3266
Hydraulic pump P3; removing......3270
Hydraulic pump P3; installing......3273
Hydraulic pump P3; checking......3276
Servo system; specifications-[4359]......3280
Servo system; specifications......3281
Servo system; description_{07-43-22}......3282
Servo system; description_{07-43-00}......3286
Lever control; electric servo; description......3290
Servo pressure; checking and adjusting......3293
Accumulator removed; checking......3296
Servo accumulator; removing......3298
Servo accumulator; installing......3300
Accumulator; discarding-......3302
Boom suspension system; component location......3304
Boom Suspension System; component description......3306
Boom Suspension System; description......3309
3rd; or 3rd_4th hydraulic function; description_{07-37-35}......3316
3rd; or 3rd_4th hydraulic function; description_{07-37-12}......3321
Boom Suspension System; specifications......3327
Boom Suspension System; tightening torques......3328
3rd_4th hydraulic function; specifications......3330
Boom suspension accumulator; checking and adjusting......3332
Boom suspension system; right accumulator; removing......3336
Boom suspension system; right accumulator; installing......3340
Boom suspension system; left accumulator; removing......3343
Boom suspension system; left accumulator; installing......3347
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing......3351
Boom suspension system; pressure reduction; safety valve; checking and adjusting......3354
Accumulator; boom suspension system; discarding......3356
Boom suspension accumulator; reconditioning......3358
3rd_4th hydraulic function; pressure; checking and adjusting......3361
3rd_4th hydraulic function; solenoid valve; replacing......3364
3rd_4th hydraulic function; shock valve; checking......3366
Boom suspension system; checking......3369
3rd_4th hydraulic; functional check......3374
Calibration of 3rd_4th hydraulic function; description......3377
92 - MECHANICAL EQUIPMENT_ATTACHMENT......3380
Attachment locking; checking......3381
Hydraulic attachment locking; description_{07-27-25}......3383
Hydraulic attachment locking; description_{07-27-02}......3390
94 - UNIT; LOAD HANDLING......3397
Lifting cylinder; description......3398
Hydraulic cylinder; piston's lock brace; installing......3400
Tilt cylinder; description......3402
Lift cylinder; tightening torques......3404
Tilt cylinder; tightening torques......3406
Lift cylinder; repacking in machine......3408
Tilt cylinder; repacking in machine......3416
Load Assist; description_{07-22-36}......3424
Load Assist; description_{07-22-13}......3430
Load Assist; description_{07-21-51}......3435
Load Assist; reference values......3440
Load Assist; front frame position sensor bracket; replacing......3442
Load Assist; position sensors; replacing_{07-20-34}......3444
Load Assist; lifting arm position sensor; bracket; replacing......3447
Load Assist; GDF linkage position sensor bracket; replacing......3449
Load Assist; pressure sensor; lift- and lower function; replacing_{07-19-23}......3451
Load Assist; pressure sensor; lift- and lower function; replacing_{07-19-01}......3454
Calibration of Load Assist; lifting arm position sensor......3456
Calibration of Load Assist; front frame position sensor......3459
Calibration of Load Assist; GDF-linkage position sensor......3462
Load Assist; component location_{07-17-02}......3465
Load Assist; component location_{07-16-39}......3467
99 - MISCELLANEOUS......3469
Fire Suppression System; tightening torques......3470
Fire suppression system; specification......3471
Fire suppression system; component location......3472
Fire suppression system; functional description......3475
Fire suppression system; component description......3481
Fire suppression system; actions after manual activation......3488
Fire suppression system; actions after activation......3509
Central lubrication system; description......3528
Pump unit; description......3533
Shift valve; description......3536
Pressure monitor; description......3538
Dosage valves; description......3540
Automatic lubrication system; specifications......3544
Recommended lubricants......3546
Grease Locations......3548
Lubrication points; central lubrication......3552
TP-Linkage's bearing points......3556
Diagnostic tools; description......3558
Parameter settings_{07-06-30}......3560
Parameter settings_{07-06-11}......3562
Software; parameter settings and read-outs......3564
Automatic lubrication pump unit; reconditioning......3571
Filling lubricant......3593
Bleeding air......3595
Change of lubrication interval......3600
System test......3602
Update of automatic lubrication system......3604
Volvo L120H Wheel Loaders Repair Service Manual
