Download Volvo Wheel Loader L120E Service and Repair Manual PDF (English)

Get the Volvo Wheel Loader L120E Service and Repair Manual PDF, a detailed technical resource for servicing, maintenance, troubleshooting, repair, and inspection of the Volvo L120E wheel loader. This manual provides useful service information, specifications, repair procedures, system details, component guidance, and maintenance instructions to help technicians and equipment owners diagnose problems and keep machinery operating efficiently. Ideal for workshop repairs, routine servicing, fault diagnosis, and professional maintenance of Volvo L120E construction equipment. www.themanualsgroup.com
 
MODEL COVERED :
Volvo L120E Wheel Loader

CONTENTS INCLUDED : 
1.L120E
Descriptions
Abbreviations, wiring diagrams
Accelerator Pedal
Air cleaner, description
Air filter pressure
Alternator, description
APS II
APS
Attachment locking
Automatic engine shut-off
Automatic lift arm lowering (Return to dig)
Axle oil temperature
Back-up alarm
Barometric pressure
Battery, description
Boom Suspension System (BSS)
Boost pressure
Brake pressure charging
Brake pressure
Brake test
Cable and component designations
Cable and component marking explanations
Camshaft speed
Camshaft, description
Central lubrication, status indication
Central lubrication
Charge-air temperature
Charging batteries
Cleanliness, brake and hydraulic systems
Comfort Drive Control, description
Communication cable explanation
Component list 1 Alternator, batteries, capacitors, electronic units
Component list 2 Diodes
Component list 3 Fuses
Component list 4 Heating coils, instruments, service connections
Component list 5 Lights
Component list 6 Control lights warning lights
Component list 7 Solenoid valves
Component list 9 Relays
Component list 10 Signals, shift solenoids
Component list 11 Sensors
Component list 12 Switches
Component list Motors, resistors, monitoring system
Connecting rod, description
Connectors, overview
Connectors, position
Control unit, description 1
Control unit, description
Control valve, description FIG1
Control valve, description
Coolant Level
Coolant temperature, engine
Coolant temperature, outlet radiator
Cooling fan adjustment
Cooling system, description
Cooling system, description1
Crankshaft, description
Cylinder head gasket, description
Cylinder head, description
Cylinder liner, description
D7 cylinder block with crankcase ventilation, description and operation
Description of table for software functions
Description torque converter
Description
Differential lock
Display panel and keypad, general
Display panel, information displays
Display panel, initial display
Display panel, operating display
Downshifting signal
Electric welding
Electrical distribution box, description
Electrical symbols and designations
Electrical system, description
Electrical system, work instructions
Electronic control system, description
Engine control unit E-ECU, description
Engine mounting, description
Engine Oil Level
Engine oil pressure
Engine Protection
Engine Shutdown
Engine speed for E-ECU
Engine speed for V-ECU
Engine timing gear, description
Engine, description 1
Engine, description 2
Engine, description
Exhaust Gas Recirculation (EGR)
Fan speed control, description
Foot brake valve, description
Frame ground connections and signal ground
Frame, description
Fuel consumption
Fuel feed pump, description
Fuel filter, description
Fuel Level
Fuel rail, description
Fuel system, description
Fuel temperature
Fully automatic
Gear Selector
Gearshifting solenoids
General description
Hand Throttle
High pressure fuel pump, description
Hydraulic Oil Level
Hydraulic oil temperature
Hydraulic power limitation
Hydraulic pump, description FIG1
Hydraulic pump, description
Hydraulic system, description FIG1
Hydraulic system, description
Increased engine rpm
Increased fan speed for AC
Indication of serious engine fault
Information display unit, general
Information display unit, setting
Injectors, description
Injectors
Instructions for working with electronic fuel injection
Instrument control unit I-ECU, description
Instruments
Internal Exhaust Gas Recirculation (IEGR), description
Interruption in computer communication
Interval Wiper
Key feed
Lighting, description
Lubrication system, description
Mechanical release of parking brake
Middle instrument panel with warning lights
Oil pump, description
Outdoor temperature
Output brake pressure
Overspeed, transmission
Parking brake, description
Parking brake
Pistons, description
Preheating coil, description
Preheating of inlet air
Protection for high fuel temperature, common rail
Recommended lubricants, oils
Reduced computer communication
Repairing hydraulic system
Reversible cooling fan, electric description
Reversible cooling fan, hydraulic diagram description
Reversible cooling fan, trouble-shooting fault indication.
Reversible cooling fan
Secondary steering, description
Secondary steering
Service display unit, axles and brakes
Service display unit, electrical control input signals 1
Service display unit, electrical control input signals 2
Service display unit, electrical control input signals 3
Service display unit, electrical control output signals 1
Service display unit, electrical control output signals 2
Service display unit, electrical system battery voltage
Service display unit, engine
Service display unit, general
Service display unit, hydraulics
Service display unit, settings
Service display unit, transmission
Service interval
Service panel, electrical feed sensor
Setting software parameters
Shift valve, description
Shift valve, function description
Soft start and safety for AC
Software functions per function group
Software, description
Speed limitation for lever steering (CDC)
Speed limitation
Starter motor engagement
Starting system, description
Steering cylinder, sectional view
Steering valve, description
Steering, description
Steering, function description
System voltage
Temperature induction air
Theft protection
Time-controlled high idle
Tire radius
Transmission disengagement
Transmission oil filter
Transmission oil level’
Transmission oil pressure
Transmission oil temperature
Transmission protection
Transmission slipping
Travelling speed
Turbine speed
Turbocharger, description
Unit pump, description
Unit pumps
Valves, description
Vehicle control unit V-ECU, description
Vibration damper, description
Vibration damper, description1
Voltage feed E-ECU, I-ECU, V-ECU
Voltage feed for sensors
Warming of hydraulic oil
Washer fluid level
Water in fuel
Wear indicator, description
Wiping during and after washing
Working on the electrical system of the machine
Diagrams
Circuit list
Explanations to hydraulic diagram
Hydraulic diagram, complete fig1
Hydraulic diagram, complete
Hydraulic diagram, fan, brake system fig 1
Hydraulic diagram, fan, brake system
Hydraulic diagram, reversible fan, brake system fig1
Hydraulic diagram, reversible fan, brake system
Hydraulic diagram, steering fig1
Hydraulic diagram, steering with CDC and secondary steering 1 fig1
Hydraulic diagram, steering with CDC and secondary steering 1
Hydraulic diagram, steering with CDC and secondary steering fig1
Hydraulic diagram, steering with CDC and secondary steering
Hydraulic diagram, steering
Hydraulic diagram, working hydraulics, differential lock fig1
Hydraulic diagram, working hydraulics, differential lock, BSS fig1
Hydraulic diagram, working hydraulics, differential lock, BSS, attachment lock, 3rd 4th function fig1
Hydraulic diagram, working hydraulics, differential lock, BSS, attachment lock, 3rd 4th function
Hydraulic diagram, working hydraulics, differential lock, BSS
Hydraulic diagram, working hydraulics, differential lock
Wiring diagram 1
Wiring diagram 2
Wiring diagram 3
Wiring diagram 4
Wiring diagram 5
Wiring diagram 6
Wiring diagram 7.1
Wiring diagram 7.2
Wiring diagram 8
Wiring diagram 9
Wiring diagram 9B
Wiring diagram 10
Wiring diagram 11
Wiring diagram 12
Wiring diagram 13
Wiring diagram 15B
Wiring diagram 16
Wiring diagram 17 Updateted CDC
Wiring diagram 17
Wiring diagram 18
Wiring diagram 19
Wiring diagram 19C
Wiring diagram 20
Wiring diagram 21B
Wiring diagram 21C
Wiring diagram 22
Wiring diagram 23
Wiring diagram 24
Wiring diagram 25
Wiring diagram 26
Wiring diagram 27
Wiring diagram 28
Wiring diagram 29
Wiring diagram 30
Wiring diagram 31
Wiring diagram 32
Wiring diagram 33
Wiring diagram 34
Wiring diagram 35
Wiring diagram 101
Wiring diagram 102
Wiring diagram 103
Wiring diagram 107
Installation Instructions
3rd hydraulic function retaining function
AC Electric fan
Attachment lock
Care track 1
Care track
Engine heater 120V 1250W
Front working lights
Heat insulation kit
Lever steering
Mounting kit, wide seat
Oil-bath air cleaner
Radio kit, right
Return to dig
Reversible fan
Single lever control
Tail lamp guard
Repair
3rd, alternatively 3rd-4th hydraulic function, max. pressure, checking and adjusting
AC relay-controlled, description
AC software-controlled, description
Accumulator, checking (removed)
Air conditioning, checking performance
Air conditioning, description
Air conditioning, troubleshooting, software-controlled ATC
ATC, description
Attachment bracket cylinder, reconditioning
Attachment locking hydraulic cylinder (vision-optimised bracket), replacing
Battery, changing
Battery, charging
Boom suspension system, accumulator, changing
Boom Suspension System, component description
Boom Suspension System, description of function
Boom Suspension System, description
Boom suspension system, hydraulic oil pressure in accumulators, depressurizing
Boom Suspension System, pressure-reducing valve, adjusting
Boom suspension system, reconditioning accumulator
Boom suspension system, test drive with load
Boom Suspension System, troubleshooting
Boom, description
Brake discs, changing
Brake discs, checking wear
Brake system, bleeding
Brake system, checking hydraulic function
Brake system, retardation, checking function
Cab suspension, description
Cab, description
Cab, installing
Cab, removing
Central block, description
Central lubrication system, description
Charging batteries
Checking LS-pressure for pump 1 (P1) and pump 2 (P2)
Components ac
Components
Compression test
Control valve, description
Coolant pump, replacing
Cooling fan hydraulics, funktion check
Cooling fan motor, replacing
Counterweight, replacing
Crankshaft, replacing front oil seal 1
Crankshaft, replacing front oil seal
Differential lock
Discarded accumulators
Drive shaft, changing
Engine ECU, removing
Engine hood, installing 1
Engine hood, installing
Engine hood, removing 1
Engine hood, removing
Engine mounting, front, replacing.
Engine, description
Engine, installing 1
Engine, installing
Engine, removing 1
Engine, removing 2
Engine, removing
Engine, tightening torques
Evaporator in air conditioning system, cleaning
Fan motor, changing
Feed pump, checking feed pressure 1
Filler grease filter, cleaning (optional equipment)
Final drive
Flexible hose, replacing
Flow control Pump 1 (P1) and Pump 2 (P2)
Foot brake pedal, adjusting angle and pedal clearance fig1
Foot brake pedal, adjusting angle and pedal clearance
Foot brake valve removed, reconditioning
Front axle, installing
Front axle, removing
Fuel control valve (FCV), checking
Fuel control valve (FCV), replacing
Fuel feed pressure, checking
Fuel filter, checking
Fuel rail pressure sensor, replacing
Fuel system, bleeding 1
Fuel system, bleeding
Fuel system, bleeding1
Function test, secondary steering
Gear selector valve, measuring resistance of solenoids
Gear selector valve, removing and installing 1
Gear selector valve, removing and installing
General description
Heat control valve, changing
Heater core, changing
High pressure fuel pump, checking
High pressure fuel pump, replacing
Hub, changing seal
Hub, changing seal1
Hub, changing seal2′
Hydraulic attachment lock (software-controlled), description
Hydraulic attachment lock with raised servo pressure, description
Hydraulic couplings, description
Hydraulic oil tank, description
Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
Hydraulic pump, checking and adjusting max working pressure
Hydraulic pump, checking and adjusting max working pressure1
Hydraulic pump, checking and adjusting standby pressure
Hydraulic pump, checking and adjusting standby pressure1
Hydraulic system, bleeding
Hydraulic system, description
Implemental attachment hydraulic cylinder, replacing
Injector, replacing
Injectors, replacing all
Lever steering CDC, checking steering signals
Lever steering, adjusting steering speed
Lever steering, checking and adjusting control valve
Lifting cylinder 1
Lifting cylinder
Lubrication cycle, description
Maintenance service, daily
Maintenance service, every 50 hours
Maintenance service, every 250 hours
Maintenance service, every 500 hours
Maintenance service, every 1000 hours
Maintenance service, every 2000 hours
Maintenance service, every 3000 hours
Maintenance service, every 4000 hours
Maintenance service, every 6000 hours
Measuring axial and radial play, rear axle mounting
Mechanical release of parking brake
Oil pan, resealing
Oil pressure, checking
Parking brake, mechanical release
Planetary gear
Precharge pressure in accumulators, checking and adjusting
Pressure in circuit, checking and adjusting
Pressure monitor, description
Pressure relief valve (PRV), checking
Pressure relief valve (PRV), replacing
Pump 3 (P3) Cooling fan pump Brake pump. Cooling fan, checking max. rpm
Pump 3 (P3) Fan pump Brake pump Fan, check max pressure
Pump 3 (P3) standby pressure, checking
Pump 3 (P3) standby pressure, checking1
Pump unit, replacing
Radiator, installing 1
Radiator, installing
Radiator, removing 1
Radiator, removing
Rear axle, installing
Rear axle, removing
Return To Dig, component position
Reversible cooling fan, funktion check
Sensor for differential lock, adjusting
Servo pressure, checking and adjusting
Servo valve, operating controls, adjusting
Servo valve, replacing
Shift valve, checking
Shock valve lift function, checking
Shock valve, tilt function, checking
Stall speed, checking
Stand-by pressure Pump 1 (P1) and Pump 2 (P2), checking and adjusting
Steer cylinder, left, changing
Steering pressure, checking and adjusting
Steering valve, reconditioning (removed)
Steering valve, replacing
Thermostat, replacing 1
Thermostat, replacing
Torque converter, removing, installing
Towing
Transmission oil pressure, checking 1
Transmission oil pressure, checking
Transmission oil pressure, checking1
Transmission oil pressure, checking2
Transmission oil pressure, checking3
Transmission, installing
Transmission, removing
Turbocharger, inspection
Valves, adjusting 1
Valves, adjusting
Viscous cab suspension, changing one unit
Warranty inspection 100 hours
Warranty inspection 1000 hours
Wheel, removing and installing
Working hydraulic system, component location
Working hydraulic system, description
Working hydraulics, troubleshooting
Working pressure Pump 1 (P1) and Pump 2 (P2), checking and adjustment
Safety
CE-marking, EMC-directive
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety when handling accumulators
Safety when handling oils and fuel
Safety when handling the machine
Safety when using lifting equipment
Safety when working on hydraulic systems
Safety when working with air conditioning refrigerant
Safety when working with batteries
Some simple rules regarding tyre handling
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working under raised boom
Service Bulletins
AC compressor, fill with oil
Action to be taken in case of abnormal lubricating oil consumption
Alternative lubricants for axles with wet brakes
Amendments in Service Manual Engine, D10B; Drive Axle, AWB 40B and Drive Axle, AWB 41 AWB 50
Automatic greasing systems of foreign manufacture
Automatic shifting (APS)
Automatic transmission lubricants
Battery and alternator test procedure
Brake return spring moved
Cable harness connector, engine
CareTrack Telematics system
D- arm cracks
D6-D7 Exhaust gas leakage into the cooling system
Decoding of radio
Delayed idle as adjustable parameter
Detecting leaks with inspection lamp
Diesel fuels – quality and function
Discontinued recommendation for usage of anti-corrosion agent in cooling system
ECU, functional check
Electrical air condition condenser fan
Engine oil requirements
Engine radiator
Engine software release W0647 for L60E-L120E Tier 2Stage 2
Exhaust insulation
Exhaust leakage into fuel system D6-D7
Final software version 2004 W35 for hardware 11184401 V-ECU
Fork arms, information warranty matters, altered procedures
Fuel in engine oil
Fuel leak
Fuel sampling, method
Gear shifting, HTE-series transmissions
Greasing of hydraulic pump drive shaft
Hydraulic power control
Improved attachment of fan grid
Improved hour recorder
Improved oil cooler housing
Improved turbo oil return pipe and clamp
Instructions for crack in lifting frame
Instructions for drilling in ROPS structure
Instructions for shielded metal arc welding
Intercooler air duct, improved hose and seals
Leakage at engine oil pump gasket
Leakage of axle oil
Limitation, TP-linkage
Loose seat base
Monitoring function for high rail pressure changed on Tier3 engines
MS.Internal.Documents
New alternator anchorage
New BSS valve
New camshaft sensor in new position
New CareTrack W-ECU2
New coolant
New engine oil level sensor
New engine software medium platform
New hardware for E-ECU
New hardware for V-ECU and software version R 2004 w 51
New hydraulic oil filter
New I-ECU introduction
New rear axle
New screws and washers for intercooler bracket
New sensor for accelerator pedal
New software for E-models
New starter switch
Non – VCE buckets and attachments
Non-return valve on the fuel return hose
Oil analyses
Oil leakage, crankshaft (oil pump side) D4D-D7D
Oil sump
Oils for Volvos wheel loaders equipped with AWB axles (Axle Wet Brakes)
O-rings with improved heat resistance
Parking brake solenoid valve
Position of orifice within the hydraulic pump compensator
Quality measures for V-ECU
Quality of illustrations in technical reports
Raising and supporting machines (up to and including the E models)
Recommendations for Oil Sampling Intervals
Reinforced screw stud
Repair instructions for attachments
Repair instructions for turbo wastegate linkage
Replaced fuel level sensor
Replacement of throttle pedal pivot pin
Replacement of turbocharger
Replacing bracket and drive belt for AC-compressor
Replacing operator seat shock absorber
Replacing parking brake seal
Replacing unit pump on engines D6D and D7D
Reporting of product misuse & near-miss report
Reports
Seals
Sensor, check
Service solution, separate belts
Specifications, stall speed
Technique and procedures when replacing valve cover gasket
Tyres, various types
Volvo Product incident accident report & Interview Form
Water separator improvement
Work instruction for campaign WLO1203 – Reinforcement of rear frame’s center hinge bearing
Special tool catalog
General
Index
Hooks
1. Enviroment and Safety equipment
2. Measuring equipment
3. Tightening and Loosening tools
4. Lifting equipment
5. Pullers and Pressing equipment
6. Drifts
7. Guide pins and Guide sleeves
8. Pliers
9. Fixtures
10. Tech Tool
11. Spare parts
Time Guide Currrent generation
Time Guide Old generation
Time Guide Previous generation

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