Volvo L120C Wheel Loader Service Manual

Service Information Document Title: Function Group: Information Type: Date: Description 000 Service Information 2014/5/27 Profile: Description The machine is a four-wheel drive loader with articulated frame steering. The engine is a six-cylinder, four-stroke, direct-injection, turbocharged, diesel engine with the designation TD63KBE (L90C), TD73KDE (L120C). The transmission is hydro-mechanical of the power shift type, where all gears are in constant mesh, with the designation HT131 for L90C and HT205 for L120C. Between the engine and the transmission there is a single stage hydraulic torque converter. Front and rear axles have fully floating drive shafts with planetary type gears in the hubs. The front axle is provided with a differential lock. The service brakes are wet type disc brakes, built integrally with the planetary gear in each wheel hub. The parking brake on L90C is of the disc brake type and it is positioned externally on the transmission output shaft. The parking brake on L120C is of the wet type disc brake and positioned inside the transmission on the output shaft. The steering system is hydrostatic with a variable axial piston pump and two hydraulic cylinders (steering cylinders). For further description of function and components, see the respective sections. Figure 1 Loader L90C / L120C

Service Information Document Title: Function Group: Information Type: Date: Product identification plates 000 Service Information 2014/5/27 Profile: Product identification plates The illustration below shows which plates should be fitted on the machine and where they are positioned. When ordering spare parts and in all enquiries by telephone or correspondence, the model designation and Product Identification Number, (PIN) should be stated. When applicable, any information on the additional plate, “INCL. PARTS” should be stated. Figure 1 Product identification plates 1. 2. 3. 4. 5. 6. 7. 8. Engine type designation, part and serial numbers are stamped into the side of the cylinder block (left side of machine) Cab type, type approval and serial number are positioned by the right roof post inside the cab. Product plate with Product Identification Number, PIN for the complete machine (shows model designation, engine manufacturer and serial number). The plate is fitted on the left side of the front frame. Model designation and serial number are also visibly stamped-in on the right side of the front frame. Additional plate to product plate, which shows machine weight, engine output, year of manufacture and has a space for the CE mark (only EU/EEA countries), is positioned below the product plate. Rear drive axle product and serial numbers are positioned on the right side of the axle housing. Transmission product and serial numbers are positioned on the right side of the transmission. Front drive axle product and serial numbers are positioned on the axle housing (above the differential lock connector). Component plate with Component Identification Number, CIN for differential carrier assembly is positioned on the lower part of the differential casing.

Service Information Document Title: Function Group: Information Type: Date: Volvo standard tightening torques 030 Service Information 2014/5/27 Profile: Volvo standard tightening torques The tightening torques in the following tables apply to bolts with a tensile strength as shown below. The tables are to be considered as a general instruction for the tightening torque of nuts and bolts unless otherwise stated. NOTE! For flange head bolts type U6FS the values should be increased by 10 %. Nuts and bolts must be cleaned and lubricated with oil. TENSILE STRENGTH 8.8 Metric coarse and fine threads Threads N m kgf m lbf ft M6 10 ±2 1.0 ±0.2 7.4 ±3.5 M8 24 ±5 2.4 ±0.5 18 ±3.5 M10 48 ±10 4.8 ±1.0 35 ±7.4 M12 85 ±18 8.5 ±1.8 63 ±13.0 M14 140 ±25 14.0 ±2.5 103 ±18.0 M16 220 ±45 22.0 ±4.5 160 ±33.0 M20 430 ±85 43.0 ±8.5 320 ±63.0 M24 740 ±150 74.0 ±15.0 550 ±110.0 TENSILE STRENGTH 10.9 Metric coarse and fine threads Threads N m kgf m lbf ft M6 12 ±2 1.2 ±0.2 9 ±1.5 M8 30 ±5 3.0 ±0.5 22 ±3.5 M10 60 ±10 6.0 ±1.0 44 ±7.5 M12 105 ±20 10.5 ±2.0 78 ±14.5 M14 175 ±30 17.5 ±3.0 130 ±22 M16 275 ±45 27.5 ±4.5 204 ±33 M20 540 ±90 54.0 ±9.0 400 ±66 M24 805 ±160 80.5 ±16.0 594 ±118 UNC threads, coarse pitch Threads N m kgf m lbf ft 1/4" 9 ±2 0.9 ±0.2 6.6 ±1.5 5/16" 18 ±4 1.8 ±0.4 13 ±3.0 3/8" 33 ±8 3.3 ±0.8 24 ±5.9 7/16" 54 ±14 5.4 ±1.4 40 ±10 1/2" 80 ±20 8.0 ±2.0 59 ±15 9/16" 120 ±30 12.0 ±3.0 89 ±22 5/8" 170 ±40 17.0 ±4.0 130 ±30 3/4" 300 ±70 30.0 ±7.0 220 ±52

7/8" 485 ±115 48.5 ±11.5 360 ±85 1" 725 ±175 72.5 ±17.5 530 ±130

Service Information Document Title: Function Group: Information Type: Date: Time Guide 070 Service Information 2014/5/27 Profile: Time Guide Regarding: L120C 16 Lubricants, fuels and other liquids Op.no. Time (h) Operation 16234 1,75 Hydraulic oil tank, changing oil and filter excl. cleaning tank 16236 2,5 Hydraulic oil tank, changing oil and filter incl.cleaning tank 16238 1,5 Transmission, changing oil and filter and cleaning suction strainer 16250 1,5 Drop box, changing oil/cleaning suction strainer 16259 1,5 Axles, changing oil 17 General 17101 0,5 Arrival inspection, according to programme 17102 1,5 Delivery inspection, according to programme 17202 3,5 Warranty inspection 100 hours, according to service programme 17204 8 Warranty inspection 1000 hours, according to service programme 17307 1,5 Maintenance service, every 250 hours 17310 3 Maintenance service, every 500 hours 17312 5 Maintenance service, every 1000 hours 17314 8 Maintenance service, every 2000 hours 21 Engine, general 21002 1,75 Compression test, engine at operating temperature 21070 7 Engine, removing 21071 40 Engine removed, general overhaul 21072 8 Engine, fitting 21102 8 Cylinder head, replacing gasket 21118 10 Cylinder heads all, replacing gaskets 21168 4 Cylinder heads all removed, decarbonizing and grinding in valves 21171 0,5 Cylinder head removed, pressure testing each 21180 4,5 Cylinder heads all, removing

21182 7 Cylinder heads all, fitting 21207 4 Cylinder block, liners removed, milling of all liner locations 21211 0,5 Cylinder, cylinder heads removed, measuring wear in all cylinders 21310 14 Cylinder liner and piston, replacing one 21318 24 Cylinder liners and pistons, replacing all 21412 1,5 Valves, adjusting 21427 0,5 Inspection cover, fitting new gasket 21436 14 Valve covers all, fitting new gasket 21493 0,5 Rocker arm mechanism removed, reconditioning 21502 6 Timing gear cover, fitting new gasket in machine 21530 7 Timing gear, replacing in machine 21532 8 Timing gear case, fitting new gasket in machine 21540 2 Injection pump, drive shaft, replacing seal 21614 2,5 Crankshaft, replacing front oil seal 21618 12 Crankshaft, replacing rear oil seal 21702 5 Sump gasket, replacing incl cleaning oil strainer 22 Lubrication and oil system 22106 0,25 Oil pressure relief valve, replacing 22114 6 Oil pump, replacing 22306 3 Oil cooler, replacing 23 Fuel system, general 23301 0,25 Fuel system, bleeding 23302 0,75 Feed pump, replacing 23304 0,5 Feed pump, checking feed pressure 23314 0,5 Fuel filters all, replacing 23315 0,25 Fuel filter extra, replacing 23410 4 Fuel tank, replacing 23601 0,5 Idling speed, checking and adjusting 23602 0,25 Stall speed, checking 23630 1,5 Injection timing, checking and adjusting 23644 1 Injection timing, checking 23673 2 Injection pump, replacing incl setting injection timing 23702 1,5 Injectors, replacing all 23704 0,75 Injector, replacing one 23707 0,25 Overflow valve, replacing 23716 1,5 Injectors, replacing copper sleeve in machine 23718 0,5 Delivery pipe, replacing one 23720 0,5 Pressure equalizer, replacing 23780 2 Injectors removed, reconditioning all

25 Inlet and exhaust systems 25102 1 Induction manifold, replacing gasket 25104 2 Exhaust manifold, replacing gasket 25220 1,5 Silencer, replacing 25221 0,5 Exhaust pipe, flexible tube, replacing 25571 1 Turbo charger, replacing 25573 2 Turbo charger removed, reconditioning 25602 0,25 Air cleaner, checking prssure drop indicator 25603 0,25 Air cleaner, primary filter replacing 25604 0,25 Air cleaner, secondary filter replacing 25606 0,75 Pre-heating coil, replacing 26 Cooling system 26104 1 Coolant, changing 26108 3 Radiator, replacing 26112 1 Radiator hose upper, replacing 26114 1 Radiator hoses lower, replacing 26202 1,5 Coolant pump, replacing 26271 1,5 Coolant pump removed, reconditioning 26298 1 Thermostat, replacing 26312 0,75 Fan belt and/or alternator belt, replacing 26322 1 Fan belt and/or alternator-, compressor belt, replacing all belts 27 Engine control 27321 0,75 Stop magnet, replacing 27323 0,5 Electrical engine shut down, check and adjusting 31 Battery and mounting parts 31101 1 Batteries, checking charging capacity 31103 0,5 Main switch, replacing 31106 0,5 Earth lead to battery, replacing 31108 1 Starter motor lead to battery, replacing 32 Alternator and charge regulator 32102 1 Alternator, replacing incl function check (no measuring instrument) 32125 0,5 Alternator, replacing carbon brush kit in machine 32205 0,5 Charging regulator, replacing 33 Starting system, general 33118 0,75 Starter motor, replacing 35 Lighting

35144 0,5 Control lamp on instrument board, replacing 35224 0,5 Head lamp assy, replacing one incl adjusting 35316 0,5 Rear lamp, replacing one 35318 0,25 Rear lamp, replacing glass or bulb 35656 0,5 Work lighting, replacing one head lamp assy 35657 0,5 Work lighting, replacing one insert 36 Other electrical equipment, general 36102 0,25 Flasher unit, replacing relay 36110 0,75 Flasher switch, replacing 36117 0,25 Flasher lamp, replacing glass or bulb 36202 0,25 Horn, replacing 36203 0,5 Reverse alarm, replacing 36216 0,75 Horn switch, replacing 36301 0,5 Windscreen wiper rear, replacing motor 36302 0,75 Windscreen wiper front, replacing motor 36303 0,75 Windscreen wiper, replacing switch 36304 0,25 Windscreen flusher pump, replacing 36404 0,25 Switch, replacing 36408 0,25 Brake light switch, replacing 36720 0,5 ECU, replacing 36721 0,5 CU 8, replacing 37 Cables and fuses, general 37201 1 Printed cercuit board, replacing 38 Instruments, sender units, warning systems 38603 0,5 Transmission oil pressure sensor, replacing 38604 0,5 Transmission temperature sensor, replacing 38605 0,5 Transmission, revolution sensor, replacing 38606 0,5 Engine temperature sensor, replacing 38607 0,5 Engine oil pressure sensor, replacing 38611 0,75 Fuel level sender, replacing 38704 0,5 Transmission temperature gauge, replacing 38705 0,5 Information display, replacing 38706 0,5 Engine temperature gauge, replacing 38711 0,5 Fuel level gauge, replacing 38720 0,5 Tachometer, replacing 42 Transmission, general 42102 0,75 Hydraulic transmission, check oil

pressure 42104 2 Oil pump, replacing 42106 1,5 Oil cooler, replacing 42108 3 Gear selector valve, replacing 42109 1 Gear selector valve removed, reconditioning 42118 16 Converter, replacing 42123 1 Lubrication and converter pressure valve, replacing 42141 1 Oil distributor and seals, replacing f and r or 1:st and f or 3:rd and f 42142 2 Oil distributor and seals, replacing 1st and 2nd or 2nd and reverse 42143 3 Oil distributor and seals, replacing 3rd and 4th or 4th and reverse 42147 0,75 Gear selector, replacing 42148 0,75 Gear selector valve, replacing one solenoid 42152 1 Seal for front output shaft, replacing 42154 1 Seal for rear output shaft, replacing 42168 7,5 Transmission, removing (upwards) 42169 8 Transmission, fitting (from above) 42171 32 Transmission removed, reconditioning 42173 9 Transmission, removing (together with engine) 42174 10 Transmission, fitting (together with engine) 45 Propeller shaft incl. bearings and mounting 45101 0,25 Propeller shaft and intermediate bearing, checking radial clearance 45102 2 Support or intermediate bearing, replacing 45104 1,5 Propeller shaft, rear, replacing 45107 1,5 Propeller shaft, in frame joint, replacing 45110 2 Propeller shaft, front, replacing 45113 1,5 Propeller shaft, removed reconditioning 46 Drive axles, general 46001 0,75 Axle suspension, measuring axial and radial clearanse 461 Null Front axle 46101 4 Axle, replacing 46111 5 Centre gear , removing and fitting 46112 6 Centre gear removed, reconditioning 46114 2 Pinion front, fitting new gasket 46142 6 Hub retainer, reconditioning one side 46143 4 Hub, replacing seal 46152 0,25 Differential lock front, repacking excl adjusting

46153 1 Differential lock, adjusting engagement 463 Null Rear axle 46301 5 Axle, replacing 46305 2 Drive shaft, replacing one side 46312 6 Centre gear removed, reconditioning 46314 2 Pinion rear, fitting new gasket 46342 6 Hub retainer, reconditioning one side 46343 4 Hub, replacing seal 51 Wheel brake, all 516 Null Front axle 51601 0,5 Brake linings, checking wear 517 Null Rear axle 51701 0,5 Brake linings, checking wear 51704 4 Brake disc, replacing both sides 51750 3 Brake piston, replacing seals 52 Hydraulic brake system 52001 0,5 Brake system, checking function, hydraulic 52002 0,5 Brake system, checking function, retardation 52004 0,5 Brake system, adjusting unloading pressure 52005 0,5 Brake system, check and adjusting pressure in circuit 52037 1 Brake system, bleeding 52508 1,75 Foot brake valve, replacing 52509 1,25 Foot brake valve removed, reconditioning 52701 0,5 Accumulator removed, checking charging pressure 52702 0,5 Accumulator, replacing 52704 2 Hydraulic pump, replacing 55 Parking brake incl.control system 55006 3,5 Parking brake, replacing discs and seals 55008 1 Parking brake, replacing control valve 64 Steering 64121 1,5 Adjustable steering column, replacing 64503 0,25 Steering system, checking working pressure 64506 1,75 Steering cylinder, replacing 64510 2 Hydraulic pump, replacing 64515 0,5 Steering system, checking and adjusting standby pressure 64520 1,75 Steering system, checking and adjusting shock and anti-cavitation-

Volvo L120C Wheel Loader Service Manual

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