Volvo L120G Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Construction L120G Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo L120G 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.
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
General fault diagnosis information.......843
Troubleshooting strategy.......845
Collection of basic data.......847
Information display; check.......850
Error codes; showing.......852
SAE error codes; translation to error messages; general.......855
Bus communication supervision.......858
Conditions when checking.......860
Lead and connector checks.......863
Troubleshooting tools.......868
Special tools for troubleshooting.......870
VCADS Pro; Error codes.......872
VCADS Pro service tool.......875
CU2501; description and measuring.......879
CU2503; description and measuring.......881
CU3605; description and measuring.......883
CU6601; description and measuring.......885
CU9901; description and measuring.......890
E-ECU PID158; description and measuring.......893
FX1005; description and measuring.......894
FX1006; description and measuring.......896
FX1007; description and measuring.......899
FX1008; description and measuring.......902
FX1009; description and measuring.......905
FX1024; description and measuring.......908
FX1025; description and measuring.......912
FX1031; description and measuring.......915
HE2501; description and measuring.......918
MA2301-MA2306; description and measuring.......920
MA2508; description and measuring.......923
MA2509; description and measuring.......925
MA2510; description and measuring.......927
MA2512; description and measuring.......930
MA2601; description and measuring.......933
MA2602; description and measuring.......935
MA4603; description and measuring.......937
MA5501; description and measuring.......939
MA5503; description and measuring.......942
MA9103; description and measuring.......944
MA9104; description and measuring.......947
MA9106; description and measuring.......950
MO2502; description and measuring.......952
MO2503; description and measuring.......954
MO2505; description and measuring.......956
MO3301; description and measuring.......958
MO3612; description and measuring.......960
MO3613; description and measuring.......962
MO6402; description and measuring.......964
MO8707; description and measuring.......966
MO8711; description and measuring.......968
Power supply; ACM (Aftertreatment Control Module); description and measuring.......970
Power supply ECC; description and measuring.......972
Power supply E-ECU; description and measuring.......974
5 V Power supply E-ECU; description and measuring.......976
Power supply I-ECU; description and measuring.......978
Power supply V-ECU; description and measuring.......980
Power supply V2-ECU; description and measuring.......982
Power supply W-ECU; description and measuring.......984
PWM2303; description and measuring.......986
PWM2602; description and measuring.......988
PWM4213 - PWM4218; description and measuring.......990
PWM5202; description and measuring.......993
PWM6601; description and measuring.......995
PWM6602; description and measuring.......997
PWM9101; description and measuring.......999
PWM9102; description and measuring.......1001
PWM9103; description and measuring.......1003
PWM9104; description and measuring.......1005
PWM9105; description and measuring.......1007
PWM9106; description and measuring.......1009
PWM9107; description and measuring.......1011
PWM9108; description and measuring.......1013
R2701; description and measuring.......1015
RE02; description and measuring.......1017
RE06; description and measuring.......1019
RE08; description and measuring.......1021
RE09; description and measuring.......1023
RE10; description and measuring.......1025
RE15; description and measuring.......1027
RE2501; description and measuring.......1029
RE6401; description and measuring.......1031
RE8712; description and measuring.......1033
SAE J1708_1587 Information link; description and measuring.......1035
SAE J1939_CAN1 Control link; description and measuring.......1038
SAE J1939_CAN2 Control link; description and measuring.......1041
SAE J1939-1 SubNet 1; description and measuring.......1044
SE2203; description and measuring.......1047
SE2301; description and measuring.......1049
SE2303; description and measuring.......1051
SE2309; description and measuring.......1054
SE2512; description and measuring.......1056
SE2513; description and measuring.......1059
SE2515; description and measuring.......1061
SE2516; description and measuring.......1063
SE2519; description and measuring.......1065
SE2520; description and measuring.......1067
SE2521; description and measuring.......1070
SE2522; description and measuring.......1073
SE2523; description and measuring.......1075
SE2524; description and measuring.......1077
SE2525; description and measuring.......1080
SE2526; description and measuring.......1082
SE2603; description and measuring.......1085
SE2604; description and measuring.......1087
SE2606; description and measuring.......1089
SE2701; description and measuring.......1091
SE2702; description and measuring.......1093
SE2703; description and measuring.......1096
SE2704; description and measuring.......1098
SE4202; description and measuring.......1100
SE4203; description and measuring.......1102
SE4209; description and measuring.......1104
SE4213; description and measuring.......1106
SE4218; description and measuring.......1108
SE4219; description and measuring.......1110
SE4307; description and measuring.......1112
SE4312; description and measuring.......1114
SE4609; description and measuring.......1116
SE5201; description and measuring.......1118
SE5203; description and measuring_{02-12-06}.......1121
SE5203; description and measuring_{02-10-06}.......1123
SE5222; description and measuring.......1125
SE5223; description and measuring.......1127
SE5501; description and measuring.......1129
SE6404; description and measuring.......1131
SE6407; description and measuring.......1133
SE6411; description and measuring.......1135
SE6601; description and measuring.......1138
SE8702; description and measuring.......1142
SE8705; description and measuring.......1144
SE8706; description and measuring.......1146
SE8708; description and measuring.......1148
SE8709; description and measuring.......1150
SE9116; description and measuring.......1153
SE9117; description and measuring.......1156
SE9119; description and measuring.......1159
SE9147; description and measuring.......1161
SE9148; description and measuring.......1164
SW2506; description and measuring.......1167
SW3630; description and measuring.......1169
SW3801; description and measuring.......1171
SW4205_SW4206; description and measuring.......1174
SW4208; description and measuring.......1177
SW4209; description and measuring.......1179
SW4211; description and measuring.......1181
SW4212; description and measuring.......1183
SW4217; description and measuring.......1186
SW4219; description and measuring.......1188
SW4220; description and measuring.......1190
SW5501; description and measuring.......1192
SW8701; description and measuring.......1194
SW9143; description and measuring.......1196
SW9148; description and measuring.......1198
SW9149; description and measuring.......1200
VCADS Pro socket; measuring.......1203
VCADS Pro; connecting problems.......1206
31 - BATTERY.......1209
System voltage.......1210
Key feed.......1212
Battery; description.......1214
Battery; weight.......1215
Battery; specifications.......1216
Battery condition; checking.......1217
Battery; charging.......1220
Batteries; replacing.......1222
32 - ALTERNATOR; CHARGE REGULATOR.......1224
Alternator; specification.......1225
Alternator 80 A; specification.......1226
Alternator; description_{12-58-27}.......1227
Alternator; description_{12-57-58}.......1233
Alternator; removing.......1234
Alternator; installing.......1238
33 - STARTING SYSTEM.......1242
Starter motor; specifications.......1243
Booting sequence.......1244
Preheating; specifications.......1246
Preheating; description.......1247
Starter lock; replacing.......1250
35 - LIGHTING.......1252
Lighting; specifications.......1253
Lighting; description.......1254
36 - OTHER ELECTRICAL EQUIPMENT.......1257
Intermittent wiper and washer.......1258
Connectors; position.......1260
Connectors; overview.......1271
Vehicle control unit V-ECU; description.......1275
Vehicle control unit V2-ECU; description.......1277
Engine control unit E-ECU; description.......1279
I-ECU MID 140 non-programmed; replacing.......1281
I-ECU MID 140 pre-programmed; replacing.......1283
V-ECU MID 187 non-programmed; replacing.......1285
V-ECU MID 187 pre-programmed; replacing.......1287
Hood opening.......1289
37 - CABLE; FUSE; RELAY.......1291
Electrical symbols and designations.......1295
Cable and component designations.......1299
Cable and component marking explanations.......1301
Components list.......1304
ACM; I_O list.......1321
ECC; I_O list.......1324
E-ECU; I_O list.......1327
I-ECU; I_O list.......1331
V-ECU; I_O list.......1335
V2-ECU; I_O list.......1340
W-ECU; I_O list.......1345
Table of contents; wiring diagrams.......1346
Wiring diagram - Start.......1349
Wiring diagram - Aftertreatment.......1353
Wiring diagram - Brake.......1358
Wiring diagram - BSS.......1362
Wiring diagram - Electrically controlled battery disconnector.......1365
Wiring diagram - Gear.......1369
Wiring diagram WD201.......1373
Wiring diagram WD202.......1377
Wiring diagram WD260.......1380
Wiring diagram WD261.......1383
Wiring diagram WD262.......1386
Wiring diagram WD263.......1390
Wiring diagram WD264.......1393
Wiring diagram WD265.......1396
Wiring diagram WD266.......1399
Wiring diagram WD267.......1404
Wiring diagram WD268.......1408
Wiring diagram WD270.......1411
Wiring diagram WD270 Update G.......1414
Wiring diagram WD301.......1417
Wiring diagram WD301 Update G_{12-15-24}.......1421
Wiring diagram WD301 Update G_{12-15-00}.......1425
Wiring diagram WD302.......1429
Wiring diagram WD303.......1432
Wiring diagram WD303 Update G.......1435
Wiring diagram WD304_{12-12-54}.......1438
Wiring diagram WD304_{12-12-28}.......1441
Wiring diagram WD306.......1444
Wiring diagram WD306 Update G.......1447
Wiring diagram WD308.......1450
Wiring diagram WD320.......1453
Wiring diagram WD321.......1456
Wiring diagram WD322.......1461
Wiring diagram WD323.......1464
Wiring diagram WD324.......1467
Wiring diagram WD325.......1470
Wiring diagram WD326.......1473
Wiring diagram WD330.......1476
Wiring diagram WD331.......1480
Wiring diagram WD333.......1484
Wiring diagram WD333 Update G.......1488
Wiring diagram WD334.......1492
Wiring diagram WD335.......1495
Wiring diagram WD335 Update G.......1498
Wiring diagram WD337 Update G.......1501
Wiring diagram WD350.......1505
Wiring diagram WD350 Update G.......1508
Wiring diagram WD351.......1511
Wiring diagram WD352.......1514
Wiring diagram WD352 Update G.......1517
Wiring diagram WD360.......1520
Wiring diagram WD361.......1523
Wiring diagram WD362.......1526
Wiring diagram WD362 Update G.......1529
Wiring diagram WD363.......1532
Wiring diagram WD363 Update G.......1535
Wiring diagram WD364 Update G.......1538
Wiring diagram WD371.......1541
Wiring diagram WD372.......1544
Wiring diagram WD373.......1547
Wiring diagram WD374.......1550
Wiring diagram WD374 Update G.......1553
Wiring diagram WD375.......1556
Wiring diagram WD375 Update G.......1559
Wiring diagram WD376.......1562
Wiring diagram WD401.......1565
Wiring diagram WD402.......1568
Wiring diagram WD403.......1571
Wiring diagram WD404.......1574
Wiring diagram WD405.......1578
Wiring diagram WD406.......1581
Wiring diagram WD501.......1584
Wiring diagram WD501 Update G.......1588
Wiring diagram WD601.......1592
Wiring diagram WD602.......1596
Wiring diagram WD604.......1599
Wiring diagram WD801.......1602
Wiring diagram WD802.......1606
Wiring diagram WD804.......1609
Wiring diagram WD804 Update G.......1612
Wiring diagram WD805.......1615
Wiring diagram WD806.......1618
Wiring diagram WD807.......1621
Wiring diagram WD808.......1624
Wiring diagram WD831 Update G.......1627
Wiring diagram WD903.......1630
Wiring diagram WD904.......1633
Wiring diagram WD905.......1636
Wiring diagram WD909.......1639
Wiring diagram WD910.......1643
Wiring diagram WD911.......1646
Wiring diagram WD911 Update G.......1649
Wiring diagram WD913.......1652
Wiring diagram WD914 Update G.......1655
Wiring diagram WD915 Update G.......1659
Battery disconnect switch; description.......1662
Chassis connection.......1664
Branching in cables.......1666
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......1672
Instrument panels.......1673
Middle instrument panel with warning lights.......1675
Information display; general.......1677
Information display; start lockout.......1680
Information display; operating display.......1682
Information display; engine.......1684
Information display; transmission.......1687
Information display; Hydraulics.......1689
Information display; axles _ brakes.......1692
Information display; electrical system.......1694
Information display; vehicle info.......1696
Information display; vehicle messages.......1699
Information display; service.......1700
Information display; service mode.......1703
Information display; settings.......1707
Alarm; description_{11-16-51}.......1709
Alarm; description_{11-16-31}.......1711
Central warning.......1713
39 - MISCELLANEOUS.......1714
CareTrack W-ECU; description.......1715
CareTrack battery; replacing.......1719
004 - POWER TRANSMISSION.......1722
40 - GENERAL.......1723
Drivetrain; component location.......1724
VCADS Pro; Operations_{11-12-52}.......1726
VCADS Pro; Operations_{11-12-32}.......1728
Error codes when Calibrating.......1730
42 - TRANSMISSION; HYDRAULIC CONTROL.......1731
Hydraulic diagram transmission - Image.......1732
Transmission; component position_{11-11-32}.......1734
Transmission; component location_{11-11-09}.......1739
Transmission; component position_{11-10-39}.......1744
Transmission; component location_{11-10-15}.......1749
Transmission; specifications_{11-09-41}.......1754
Transmission; specifications_{11-09-18}.......1756
Hydraulic transmission; capacity.......1758
Transmission; tightening torques_{11-08-22}.......1759
Transmission; tightening torques_{11-07-59}.......1761
Hydraulic transmission; description.......1763
Transmission; specifications_{11-06-34}.......1771
Transmission; specifications_{11-06-11}.......1773
Transmission; removing.......1775
Transmission; installing.......1786
Hydraulic diagram transmission_{11-03-21}.......1795
Hydraulic diagram transmission_{11-02-58}.......1798
Lock up valve; replacing.......1801
Transmission oil pressure; checking_{11-01-44}.......1803
Transmission oil pressure; checking_{11-01-21}.......1807
Gear selector valve; replacing one solenoid.......1812
Seal for front output shaft; replacing.......1816
Seal for rear output shaft; replacing.......1819
Transmission; function check_{10-59-11}.......1822
Transmission; function check_{10-58-51}.......1823
Transmission; calibration.......1824
45 - PROPELLER SHAFT.......1826
Propeller shaft; tightening torque.......1827
Propeller shaft; component description.......1828
46 - FRONT AXLE; REAR AXLE.......1830
Drive axles; description.......1831
Front and rear axles; tightening torque.......1833
Front and rear axles; specifications.......1834
Front axle; component description.......1835
Rear axle; component description.......1838
Rear axle mounting; component description.......1842
Front and rear axles; volume.......1845
Automatic differential brake; Limited Slip; description.......1846
Rear axle mounting; volume.......1849
Hub seal; replacing.......1850
Hub reduction; Removing.......1868
Hub reduction; Installing.......1871
Axle; removing.......1873
Axle suspension bushes and seals; replacing.......1877
Axle suspension; tightening torque.......1888
Axle; installing.......1889
Hub reduction; removing.......1893
Hub reduction; installing.......1896
Differential lock; description.......1898
Differential lock; adjusting.......1900
Differential lock; function check.......1905
49 - MISCELLANEOUS.......1907
Oil cooler; component description.......1908
Heat exchanger; replacing.......1909
005 - BRAKE.......1913
50 - GENERAL.......1914
VCADS Pro; Operations-.......1915
Tech Tool; operations.......1916
51 - WHEEL BRAKE.......1917
Wheel brake; specification.......1918
Brake discs; measuring wear.......1919
Wheel brakes function; checking.......1922
Brake discs; replacing.......1923
Brake piston seals; replacing-.......1929
Brake disc; replacing.......1934
Brake piston seals; replacing.......1940
52 - HYDRAULIC BRAKE SYSTEM.......1945
Brake system; component location_{10-35-21}.......1946
Brake system; component location_{10-34-59}.......1949
Braking system; description_{10-34-24}.......1952
Braking system; description_{10-34-02}.......1957
Brake system; specifications.......1961
Brake system circuit pressure; checking and adjusting.......1962
Brake system; bleeding_{10-32-41}.......1965
Brake system; bleeding_{10-32-18}.......1967
Brake system retardation function; checking.......1969
Automatic brake function; checking.......1970
Brake system charging; checking.......1972
Axle oil cooler; component location.......1977
Axle oil cooler; description.......1979
Foot brake valve; description.......1982
Automatic brake valve; description.......1983
Brake accumulator; description.......1985
Brake accumulator; specifications.......1987
Accumulator (removed) charging pressure; checking.......1988
Accumulator; removing.......1990
Accumulator; installing.......1992
Accumulators; checking in machine.......1994
Accumulator; Discarding.......1996
55 - PARKING BRAKE.......1999
Parking brake; specifications.......2000
Parking brake; component location.......2001
Parking brake; component description.......2003
Parking brake; function description.......2005
Parking brake discs and seals; replacing.......2011
Parking brake function; checking.......2017
006 - STEERING.......2019
60 - GENERAL.......2020
Steering system; component location.......2021
Steering system; description.......2023
Steering system function; checking.......2031
VCADS Pro; operations.......2033
Lever steering CDC; tightening torques.......2034
64 - STEERING.......2036
Steering; specifications.......2037
Steering cylinder removed; reconditioning incl replacing bearings.......2038
Steering cylinder; description.......2044
Steering valve; description.......2046
Steering cylinder; tightening torque.......2048
Shift valve; Description.......2050
Steering system working pressure; checking and adjusting.......2053
Left steering cylinder bearings; replacing.......2056
Right steering cylinder; replacing bearings.......2066
Left steering cylinder; removing.......2073
Right steering cylinder; removing.......2082
Steering cylinder removed; reconditioning excl replacing bearings.......2089
Left steering cylinder; installing.......2093
Right steering cylinder; installing.......2101
Steering cylinder; repacking.......2108
Accumulator; discarding-.......2111
Secondary steering pump; specifications.......2113
Secondary steering; component location.......2114
Secondary steering; description.......2116
Secondary steering pump; description.......2120
Pressure monitor; description .......2121
Secondary steering pump working pressure; checking and adjusting.......2123
66 - LEVEL STEERING.......2125
Comfort Drive Control (CDC); description.......2126
CDC valve; lever steering; description.......2131
Lever steering (CDC); specifications.......2134
Comfort Drive Control (CDC); component location.......2135
Comfort drive control (CDC) angle sensor; changing.......2137
Comfort Drive Control; servo pressure; checking.......2140
Error codes when calibrating .......2142
Comfort Drive Control (CDC) joystick; changing.......2145
Comfort drive control (CDC) solenoid valve; changing.......2150
Lever steering (CDC) function; checking.......2152
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......2155
70 - GENERAL.......2156
Frame; description.......2157
71 - FRAME.......2160
Counterweight; tightening torques.......2161
Counterweight; weight.......2162
Counterweight; removing.......2164
Counterweight; installing.......2167
74 - FRAME LINK.......2171
Frame joint; tightening torques.......2172
Frame joint; description.......2173
Frame joint; replacing bearings.......2175
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......2196
Wheel; tightening torque.......2197
Rear wheel; removing.......2198
Rear wheel; installing.......2200
Front wheel; removing.......2202
Front wheel; installing.......2204
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......2206
80 - GENERAL.......2207
Cab; description.......2208
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.......2210
Plastic hood; repairing.......2211
Engine hood; raising and securing.......2216
Engine hood; removing.......2218
Engine hood; installing.......2222
Actuator; replacing.......2226
Engine hood; manually operating.......2231
83 - DOORS; HATCH; COVER PLATE; (all).......2234
Electric door opener; description.......2235
Electric door opener; control unit; replacing.......2239
Electric door opener; locking motor; replacing.......2241
Electric door opener; rotor switch; replacing.......2243
Electric door opener; opening support motor; replacing.......2245
Door lock cylinder; replacing_{09-23-32}.......2248
Door lock cylinder; replacing_{09-23-09}.......2256
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......2264
Windows; general.......2265
Side window; replacing_{09-21-04}.......2267
Windscreen; replacing_{09-20-32}.......2277
Window pane; installing.......2287
Windows; general; gluing.......2292
85 - CAB INTERIOR; UPHOLSTERY.......2295
Operator's seat; securing.......2296
87 - AIR CONDITIONING UNIT.......2298
Climate control system; description.......2299
ECC MID 146 non-programmed ECU; replacing.......2304
ECC MID 146 pre-programmed ECU; replacing.......2307
Troubleshooting; air conditioning unit (AC).......2310
Climate unit; removing.......2314
Climate unit; installing.......2322
Pause heater; description.......2328
Pause heater; replacing.......2330
Fan motor; replacing.......2333
Air mix door actuator; replacing.......2336
Heater core; replacing.......2342
Heat control valve; replacing.......2345
Air conditioning; tightening torques.......2349
Air conditioning; specifications.......2350
Air conditioning; refrigerant; weight_{09-10-30}.......2352
Air conditioning; refrigerant; weight_{09-10-10}.......2353
Air conditioning; checking performance.......2355
Drying filter; replacing.......2357
Condenser; replacing.......2361
Compressor; replacing.......2367
Evaporator; replacing.......2373
Expansion valve; replacing.......2381
Refrigerant; draining.......2392
Refrigerant; filling incl vacuum pumping.......2395
88 - INTERIOR EQUIPMENT.......2399
Accelerator pedal; replace.......2400
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......2402
90 - GENERAL.......2403
Hydraulic diagram; complete - Image.......2404
Hydraulic diagram; basic machine - Image.......2406
Explanations to hydraulic diagram.......2407
Hydraulic components; cleanliness when handling.......2416
Hydraulic diagram; complete_{09-00-48}.......2419
Hydraulic diagram; complete_{09-00-26}.......2422
Hydraulic diagram; basic machine.......2425
Hydraulic system; volume.......2428
Hydraulic system; bleeding.......2429
V2-ECU; MID 249; changing non-programmed ECU.......2432
V2-ECU; MID 249; changing pre-programmed ECU.......2434
Hydraulic system; warming up.......2436
Control valve; tightening torques.......2438
Accumulator; discarding .......2439
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......2442
Error codes when calibrating.......2445
Hydraulic oil tank; description.......2449
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump.......2451
Hydraulic connections; tightening torques.......2453
Hydraulic couplings.......2455
Working hydraulic system; component location.......2459
Working hydraulic system; description.......2461
Control valve; description.......2469
Central valve; description.......2473
Control valve; specifications.......2475
Back-up valve; checking and adjusting.......2476
Shock valve lift function; checking.......2479
Shock valve; tilt function; checking.......2482
Back-up valve; replacing.......2485
Lift; solenoid valve; changing.......2488
Lower; solenoid valve; changing.......2490
Tilt in; solenoid valve; changing.......2492
Tilt out; solenoid valve; changing.......2494
Lift_lower; angle sensor; changing.......2496
Tilt in_out; angle sensor; changing.......2499
Tilt; checking.......2510
Lift_lower function; checking.......2512
Hydraulic pumps; description.......2516
Hydraulic pump flow regulation; description.......2518
Hydraulic pump (P1); specifications.......2522
Hydraulic pump (P2); specifications.......2523
Hydraulic pump (P3); specifications.......2524
Function times; specifications.......2525
Hydraulic pumps; tightening torques.......2526
Lifting time; checking.......2527
Hydraulic pump; standby pressure and working pressure; checking and adjusting.......2528
LS (load sense) pressure; checking.......2532
Hydraulic pump P1; removing.......2535
Hydraulic pump P1; installing.......2540
Hydraulic pump P2; removing.......2544
Hydraulic pump P2; installing.......2549
Hydraulic pump P3; removing.......2553
Hydraulic pump P3; installing.......2556
Hydraulic pump P3; checking.......2559
Servo system; specifications.......2562
Single lever control electric servo; replacing.......2563
Servo pressure; checking and adjusting.......2574
Servo pressure; at the spool in control valve; checking.......2577
Accumulator removed; checking.......2579
Servo accumulator; removing_{08-33-21}.......2581
Servo accumulator; removing_{08-32-58}.......2583
Servo accumulator; installing_{08-32-13}.......2585
Servo accumulator; installing_{08-31-51}.......2587
Accumulator; discarding.......2589
Boom suspension system; component location.......2591
Boom Suspension System; component description.......2593
Boom Suspension System; description.......2596
3rd; or 3rd_4th hydraulic function; description.......2601
Boom Suspension System; specifications.......2606
Boom Suspension System; tightening torques.......2607
3rd_4th hydraulic function; specifications.......2609
3rd_4th hydraulic function; tightening torques.......2610
Boom suspension accumulator; checking and adjusting.......2611
Boom suspension system; right accumulator; removing_{08-26-40}.......2615
Boom suspension system; right accumulator; removing_{08-26-18}.......2619
Boom suspension system; right accumulator; installing_{08-25-45}.......2623
Boom suspension system; right accumulator; installing_{08-25-24}.......2627
Boom suspension system; left accumulator; removing_{08-24-50}.......2630
Boom suspension system; left accumulator; removing_{08-24-28}.......2634
Boom suspension system; left accumulator; installing_{08-23-54}.......2638
Boom suspension system; left accumulator; installing_{08-23-35}.......2642
Boom suspension system; hydraulic oil pressure in accumulators; depressurizing.......2645
Boom suspension system; pressure reduction; safety valve; checking and adjusting.......2648
Accumulator; boom suspension system; discarding.......2650
Boom suspension accumulator; reconditioning.......2652
3rd_4th hydraulic function; pressure; checking and adjusting.......2655
3rd_4th hydraulic function; solenoid valve; replacing.......2658
3rd_4th hydraulic function; shock valve; checking.......2661
Boom suspension system; checking.......2664
3rd_4th hydraulic; functional check.......2669
3rd; or 3rd_4th hydraulic function; component location.......2672
92 - MECHANICAL EQUIPMENT_ATTACHMENT.......2674
Hydraulic attachment bracket; description.......2675
Attachment locking; checking.......2680
94 - UNIT; LOAD HANDLING.......2682
Hydraulic cylinder; piston's lock brace; installing.......2683
Lift cylinder; tightening torques.......2685
Tilt cylinder; tightening torques.......2687
Lift cylinder; repacking in machine.......2689
Tilt cylinder; repacking in machine.......2706
99 - MISCELLANEOUS.......2721
Fire suppression system; specification.......2722
Fire suppression system; component location.......2723
Fire suppression system; functional description.......2725
Fire suppression system; component description.......2729
Fire suppression system; actions after manual activation.......2736
Fire suppression system; actions after activation.......2754
Central lubrication system; description.......2771
Pump unit; description.......2776
Shift valve; description.......2779
Pressure monitor; description.......2781
Dosage valves; description.......2783
Automatic lubrication system; specifications.......2787
Recommended lubricants.......2789
Grease Locations.......2791
TP-Linkage's bearing points.......2795
Diagnostic tools; description.......2797
Parameter settings.......2799
Software; parameter settings and read-outs.......2801
Automatic lubrication pump unit; reconditioning.......2808
Filling lubricant.......2830
Bleeding air.......2832
Change of lubrication interval.......2838
System test.......2840
Update of automatic lubrication system.......2842
Volvo L120G Wheel Loaders Repair Service Manual
