VOLVO L120E Wheel Loader Full Service Repair Manual

VOLVO WHEEL LOADER L120E

2 Volvo has developed and manufactured wheel loaders for half a century. The goal has always been to create the optimal machine for maximum performance and productivity, high operator comfort, and unmatched flexibility. Now, the latest experiences and leading technology have resulted in the Volvo L120E. The high performance, low emission engine delivers close to maximum power already at low rpm. Furthermore, the powerful patented TP linkage, combined with Volvo’s purpose-built range of attachments, provides the flexibility needed to handle a variety of tasks. Advanced technology helps to make this a swift, versatile and fuel efficient production machine in any application. Get more done You’ll find the L120E a pleasure to operate. In this respect, competing loaders simply can’t compete. It’s powerful, agile and easy to maneuver. Sitting comfortably in an ergonomically designed seat, you have total control L120E - STRONG AND VERSATILE over the machine. Engine and hydraulics respond immediately to your commands. Visibility is panoramic and the air in the cab is always fresh. Both operator and machine get more done with a lot less waste. A great deal for your investment Proven reliability, excellent financing, extremely low fuel consumption and a high trade-in value provide the cornerstones of a safe investment. Add to that outstanding handling and productivity, a market-leading operator environment to protect the person in the machine, quick and simple daily maintenance and modest service requirements. And what do you get? The most cost efficient loader in its class, delivering unparalleled profitability – both now and in years to come. With the L120E, everybody is a winner. Quite simply, a great deal for your money. Volvo’s 20 ton wheel loader is packed with loads of power to make your job easier everyday. The tireless L120E represents yet another leap in the stride for higher productivity. The versatility of this Volvo wheel loader makes it the obvious choice in a wide range of industries and applications, including moving material in sand and gravel pits, loading cargo vessels and rail cars, handling wood chips at paper mills and unloading timber trucks. Specifications L120E Engine: Volvo D7D LA E2 Max power at 30,0 r/s (1800 rpm) SAE J1995 gross: 165 kW (224 hp) ISO 9249, SAE J1349 net: 164 kW (223 hp) Breakout force: 149,3 kN* Static tipping load at full turn: 11 670 kg* Buckets: 2,6 – 9,5 m 3 Log grapples: 1,1 – 2,4 m 2 Operating weight: 19,0 – 21,0 t Tires: 23.5 R25 750/65 R25 * Bucket: 3,4 m 3 with bolt-on dges, tires 23.5 R25 L3, standard boom

4 The only thing modest about this machine is its fuel consumption Even at low rpm, the 7-liter high performance engine delivers full power and maximum torque. The machine responds quickly and forcefully with excellent rimpull, full hydraulic power, low fuel consumption and low emissions. And thanks to the low rpm performance, the service life of the engine is extended. Responds to your commands The Volvo fully automatic countershaft transmission provides smooth and effective gear shifting. All the operator has to do is select forward or reverse and APS automatically selects the right gear according to both engine rpm and ground speed. Volvo’s in-house engineered axles and drivetrain are well matched and designed for top dependability. And Volvo’s oil circulation cooled wet disc brakes provide smooth, effective braking – and, of course, a long service life. POWER UP YOUR PRODUCTION Torque Parallel linkage – a breakthrough in the industry The reliable TP linkage, Volvo’s patented lift-arm system, delivers high and even breakout torque throughout the entire lifting range. The system is exceedingly user-friendly. The operator can easily handle heavy materials and maintain full control in all positions. Hydraulics that make sense The Volvo L120E features an intelligent load sensing system for both the main and steering hydraulics. Two variable piston pumps provide the exact ﬂow and pressure required at any given moment, distributing power when and where it’s needed. In addition to rapid response, this system facilitates smoother operation, lower fuel consumption, and precise control, even at low rpm. Load more tons per hour with the Volvo L120E. Its powerful engine and the Automatic Power Shift (APS) gear shifting system provide immediate response even in the toughest conditions. And Volvo axles are designed to ensure that the rimpull is there when needed. Torque Parallel linkage (TP linkage), load sensing hydraulics, smooth steering and stable operation help make the L120E a precision performer. Engine • Volvo D7D, a turbocharged, air-to-air intercooled low emission engine with electronically controlled fuel injection delivers high torque even at low rpm. • The electronically controlled hydrostatic fan is only activated when necessary, thus saving fuel. Transmission • With Volvo’s 3rd generation of APS, the operator can select between four different operating modes, including the new AUTO function, which adaptively chooses the most convenient shifting program for the job at hand, equally weighing the operator’s driving habits together with the operating cycle. • The 3rd generation APS now has fully automatic shifting 1-4, meaning all the operator has to do is choose forward or reverse. Axles/Brakes • The Volvo axles are fully integrated with the drivetrain, delivering superior rimpull. • Oil circulation cooled wet disc brakes ensure effective braking and a long service life. • An electronic brake test in Contronic gives you instant access to the status of the brakes. • A brake wear indicator on each wheel allows you to easily check the brake pad wear. Steering • Load-sensing steering only uses power when it’s needed, thereby saving fuel. • E-series loaders feature an accumulator system, providing stable, smooth steering and greater safety. Frame • Rugged frame design for secure mounting of components increases the service life of the machine. • Volvo’s frame joint bearing design is a well-proven concept that’s easy to maintain and renowned for its long service life.

5 TP linkage • Unique patented lift-arm system, which provides two solutions in one: excellent breakout torque and parallel action throughout the entire lifting range. Load-sensing hydraulics • The load-sensing hydraulic system ensures that hydraulic oil is pumped around the system only when and where it’s needed. This means greater efﬁciency and lower fuel consumption. • Pilot-operated hydraulics allow precise control of the attachments, making life easier, and safer, for the operator.

6 A clean and comfortable workplace The right cab climate does wonders for efficiency, keeping operators sharp during long shifts. In fact, all incoming air is filtered in two stages, making this one of the cleanest cabs on the market. Even the recirculated air is filtered. Furthermore, Volvo’s state-of-the-art air-conditioning* provides a pleasant temperature year-round, regardless of outdoor conditions. So even after a long work shift, the air in the cab is still fresh and the operator’s mind is still clear. Comfort and productivity go hand- in-hand There is a range of comfortable seats, all of them with multiple adjustment functions for optimal individual comfort. All instruments are visible at a glance, and all important information is right in front of the operator. The forward, reverse and kick-down functions are situated both on the lever on the left-hand side of the steering wheel and on the hydraulic console to the right. And thanks to Comfort Drive Control (CDC)*, you can steer, change directions and kickdown to first gear with easy-to-use controls integrated into the left-hand armrest – an excellent way to combat fatigue and static muscle strain. Furthermore, to avoid monotonous arm movements, you can shift at any time from lever steering to using the steering wheel. AN ALERT OPERATOR IS A PRODUCTIVE OPERATOR Contronic keeps an eye on everything Contronic, the highly reliable control and monitoring system from Volvo, continuously monitors the machine’s operation and performance. The system is an electronic network made up of three computers. Operating at three levels, the system keeps an eye on the machine’s various functions in real-time. If a potential problem should occur, the system generates an immediate warning, making the operator aware of the condition. All operating data is saved and can be used to analyze how the machine performs and also to trace its history since the latest service. The machine’s functions can be updated for optimal adaptation to new and changing operating conditions via the Contronic service display tool. With VCADS Pro, it’s also possible to check and adjust the machine’s functions and performance characteristics. Low noise levels Thanks to its ingenious rubber mounting system and heavy-duty insulation, the Care Cab is one of quietest cabs on the market. By reducing tiresome earfuls and annoying vibrations, the operator will stay sharp throughout the shift. In short, it’s a great place to work. Volvo Care Cab with the Contronic monitoring system reinforces Volvo’s reputation as a leader in operator environments and cab comfort. We never forget the operator inside the machine. A comfortable, operator-friendly and safe environment makes the workday easier and more productive. Care Cab • Unrivalled operator environment with one of the market’s best cab filtration systems. • Pleasant interior with superior finish makes it easy to maintain and keep clean. • Adjustable seat, armrest, hydraulic lever console and steering wheel* for optimal operator comfort and high production. • Contronic, a superior control and monitoring system, designed to increase safety and productivity. • All service platforms and entry ladders boast improved anti-slip surfaces. Sloped entry ladder for easy cab access. • Large windscreens, narrow pillars and a sloped engine hood ensure good panoramic visibility, thus further increasing safety. • Powerful halogen lighting to the front and rear provides good visibility over the entire work area. * Optional equipment

8 A winner for years to come Your Volvo L120E has to be a winner – both in day-to-day and long-term operations, always operating economically with maximum consideration of the environment. The machinery has to be trusted in all aspects. It must deliver the anticipations of productivity and economy. High quality and easy maintenance are imperative for keeping up the work process. The high performance low emission engine is both good for your business and for the environment. Comfortable and quiet operator´s environment The operator inside deserves a comfortable, reliable and safe machine to work with. A good environment helps to spare operator, equipment and nature for years to come. The Volvo L120E is a super competitive wheel loader that puts the operator right in the middle, literally speaking. Tedious vibrations and noise have been heavily reduced. If the operator feels comfortable and secure, it’s easier to stay attentive. VOLVO’S COMMITMENT TO NATURE AND MANKIND More than 95% recyclable The L120E is almost completely recyclable. We see it as a natural step in our commitment. Components such as the engine, transmission and hydraulics are re-engineered and re-used in our Parts Exchange program. The equipment has to be as trustworthy, service-friendly, productive and as cost-effective as possible. Choose this wheel loader for maximum productivity and minimal impact on operator, machinery and environment. Feel free to feel secure in a Volvo L120E. Quality, safety, and care for the environment are Volvo’s core values. Indeed, we see our commitment as an integral part of our operation. Few machines have to work in tougher conditions. The ultimate goal is maximized productivity and efficiency for the lowest cost per hour, with minimized environmental impact. For instance, plants and manufacturing processes are certified in accordance with ISO 14001. This is but one example of our tangible commitments and high quality standards. And that’s why Volvo customers get one of the most environmentally considerate and dependable wheel loaders on the market. Quality • The air is vented from all major components with easy to replace breather filters, used to prevent dirty air from entering the transmission, axles, fuel tank, and hydraulic tank. • All electrical wires are routed through sturdy conduits, protected from water, dust, and abrasion with rubberized connectors and terminal caps. • The L120E is designed from the beginning for easy service and maintenance. Easy access to all components lays the foundation for shorter service and maintenance time and longer life. Safety • A dual-circuit service brake system that fulfills all requirements according to ISO 3450, electronic brake test in Contronic and easy to check brake wear indicators are all ways to ensure safe and effective braking. • Volvo Care Cab is tested and approved according to ROPS ISO 3471 and FOPS ISO 3449 standards. • Optimized panoramic visibility gives effective control over the entire work area. • The L120E has steps and platforms that are equipped with anti-slip surfaces and well positioned hand rails. Environment • The low rpm, high performance D7D engine meets all current emission requirements according to step 2 legislation in Europe and the US. • The L120E is manufactured in environmentally certified factories according to ISO 14001. • The L120E is more than 95% recyclable according to material weight. • Low external and internal sound levels.

10 (L120E) VOLVO L120E IN DETAIL Engine 7 liter, 6-cylinder straight turbocharged diesel engine with electronically controlled unit pumps and conventional injectors. The engine has wet replaceable cylinder liners and replaceable valve guides and valve seats. The throttle application is transmitted electrically from the throttle pedal or the optional hand throttle. Air cleaning: three-stage. Cooling system: Air-to-air intercooler and hydrostatic, electronically controlled fan. Brake system Service brake: Volvo dual-circuit system with nitrogen charged accumulators. Outboard mounted hydraulically operated, fully sealed oil circulation cooled wet disc brakes. The operator can select automatic declutch of the transmission when braking through Contronic. Parking brake: Fully sealed, wet multi-disc brake built into the transmission. Applied by spring force and electro-hydraulically released with a switch on the instrument panel. Secondary brake: Dual brake circuits with rechargeable accumulators. Either one circuit or the parking brake fulﬁlls all safety requirements. Standard: The brake system complies with the requirements of ISO 3450. 800 1000 1200 1400 1600 1800 2000 r/min 15 20 25 30 35 r/s Torque Torque Economic working range hp Power Power lbf ft 700 600 500 400 800 1200 1000 800 600 400 Nm kW 220 200 180 160 140 120 100 80 300 250 200 150 100 Engine Volvo D7D LA E2 Max power at 30,0 r/s (1800 r/min) SAE J1995 gross 165 kW (224 hp) ISO 9249, SAE J1349 164 kW (223 hp) Max torque at 23,3 r/s (1400 r/min) SAE J1995 gross 1020 Nm ISO 9249, SAE J1349 1015 Nm Economic working range 1100–1600 r/min Displacement 7,1 l Drivetrain Torque converter: single-stage. Transmission: Volvo countershaft transmission with single lever control. Fast and smooth shifting of gears between forward and reverse with Pulse Width Modulation (PWM) valve. Gear shifting system: Volvo Automatic Power Shift (APS) with fully automatic shifting 1-4 and mode selector with 4 different gear shifting programs, including AUTO. Axles: Volvo fully ﬂoating axle shafts with planetary hub reductions and cast steel axle housings. Fixed front axle and oscillating rear axle. 100% differential lock on the front axle. Transmission Volvo HTE 205 Torque multiplication 2,85:1 Maximum speed, forward/reverse 1 7,1 km/h 2 13,1 km/h 3 24,7 km/h 4 35,1 km/h Measured with tires 23.5 R25 L3 Front axle/rear axle Volvo/AWB 31/30 Rear axle oscillation ±13° Ground clearance at 13° oscillation 460 mm Number of brake discs per wheel front/rear 1/1 Accumulators 3x1,0 l Accumulator for parking brake 1x1,0 l Voltage 24 V Batteries 2x12 V Battery capacity 2x140 Ah Cold cranking capacity, approx 1050 A Reserve capacity, approx 270 min Alternator rating 1540 W/55 A Starter motor output 5,4 kW (7,3 hp) Electrical system Central warning system: Central warning light for the following functions, (buzzer with gear engaged): Engine oil pressure, transmission oil pressure, brake pressure, parking brake applied, hydraulic oil level, axle oil temperature, steering system pressure, low coolant level, coolant temperature, transmission oil temperature, hydraulic oil temperature, overspeeding in engaged gear, brake charging, fuel temperature, charge air temperature.

VOLVO L120E Wheel Loader Full Service Repair Manual

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