Complete service repair manual with Electrical Wiring Diagrams for Volvo BM L120 / L120B Wheel Loaders.
Volvo BM L120B Wheel Loaders Parts Catalog.pdf
Volvo BM L120B Wheel Loaders Service Repair Manual.pdf (bonus material)
Volvo BM L120 Wheel Loaders Parts Catalog.pdf
PRODUCT DETAILS:
Total Pages: 2,321 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
Volvo BM L120 Parts Catalog…………….2
0 – GENERAL…………….3
03 – SPECIFICATIONS…………….4
Product identification plate…………….5
2 – ENGINE WITH MOUNTING AND EQUIPMENT…………….6
21 – ENGINE…………….7
Repair kits…………….8
Engine with fitting parts…………….15
Cylinder block…………….19
Crankshaft and related parts…………….23
Camshaft…………….28
Timing gear casing and gears…………….30
Cylinder head…………….34
Engine mounting…………….37
22 – LUBRICATING SYSTEM…………….40
Lubricating oil system…………….41
Oil pump…………….45
Oil cooler …………….48
Oil filter…………….50
Housing; oil filter…………….53
Oil filler and dipstick…………….56
23 – FUEL SYSTEM…………….58
Fuel system…………….59
Fuel pipes; fuel injection pump – fuel filter…………….62
Fuel lines; injectors…………….66
Fuel tank…………….69
Fuel filter…………….73
Injection pump with drive…………….76
Injection pump…………….80
Centrifugal governor…………….85
Smoke limiter…………….91
Feed pump…………….95
Injector…………….97
Slurry separator…………….101
Extra fuel filter 90656; IRAN…………….104
25 – INLET & EXHAUST SYSTEM…………….106
Inlet system…………….107
Air filter-[4755]…………….110
Exhaust system…………….112
Turbocharger with fitting parts…………….115
Turbo charger STD…………….118
Oil bath filter 90677…………….121
Air filter…………….124
Pre cleaner cyclone type 90943…………….126
26 – COOLING SYSTEM…………….129
Cooling system …………….130
Radiator with fitting parts…………….134
Fan shroud STD USA…………….139
Belt transmission…………….142
Water pump and thermostat housing…………….146
Cooling system oil cooler…………….150
Coolant filter STD USA SER NO – 60652; 91010…………….153
Coolant filter STD USA SER NO 60653 -; 91876…………….156
Intercooler 91151; 91351…………….158
Inlet manifold 91151; 91351…………….161
27 – ENGINE CONTROL…………….163
Regulator control…………….164
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS…………….168
31 – BATTERY…………….169
Battery with assembling details…………….170
Battery box…………….174
32 – ALTERNATOR; CHARGE REGULATOR…………….177
Alternator with assembling details…………….178
Alternator-[3945]…………….181
Brushles alternator 050a 91467…………….184
Alternator…………….187
33 – STARTING SYSTEM…………….190
Starter motor…………….191
35 – LIGHTING…………….195
Lighting…………….196
Lighting STD USA; 98274; 98275; 98276; 98800…………….201
Headlamp…………….204
Rotating beacon 99886-[3655]…………….206
Rotating beacon 99886…………….209
License plate lamp 90645…………….212
Protection front lighting 90617…………….215
36 – OTHER ELECTRICAL EQUIPMENT…………….217
Windscreen wiper; horn; reverse-motion alarm…………….218
Windshield wiper…………….221
Windshield washer…………….224
Comfort drive control; electrical system 91222…………….227
Cable harness for Cdc-steering 91880…………….230
Auxiliary steering system 90768 …………….234
37 – CABLE; FUSE; RELAY…………….237
Electrical system; cab…………….238
Kickdown function 91641…………….242
Kickdown function 91952…………….245
Electric system front…………….248
Bucket automatic and lift automatic…………….251
Electric system rear…………….253
Electrical distribution box…………….259
Parking brake alarm 90674…………….266
Starter element with fitting parts STD USA; IRAN; 90669; 91151; 91351…………….269
Pre-heater…………….273
Fan 90317…………….275
Attachment locking; electrical system 91271; 91634…………….278
Boom suspension system; electrical system 91826…………….281
Cable harness for air conditioning 91199-[2851]…………….284
Cable harness for air conditioning 91199…………….287
Cable harness 005th function 90819…………….290
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM…………….292
Instrument panel…………….293
Instrument panel and instruments…………….298
Tacometer _ speedometer 91485…………….303
Instruments panel 91475; 91477; 91480…………….306
4 – POWER TRANSMISSION…………….309
41 – CLUTCH; TORQUE CONVERTER…………….310
Repair kit…………….311
Torque converter SER NO – 5154; 5162 – 5167; (USA) SER NO – 60117…………….315
Torque converter-[2508]…………….318
Torque converter…………….321
42 – TRANSMISSION; HYDRAULIC CONTROL…………….324
Hydraulic transmission with fitting parts…………….325
Converter housing with assembly parts…………….329
Clutch housing with fitting parts…………….334
Clutches; gears and shafts…………….337
Clutches forward and reverse…………….341
Clutches 001st and 2nd speeds…………….345
Clutches 003rd and 4th speeds HT – 6139…………….348
Clutches 003rd and 4th speeds HT 6140 -…………….352
Hydraulic lines; valves and filter…………….356
Gear selector valve…………….361
Valves-[2053]…………….364
Transmission pump…………….367
Valves …………….370
Pump drive…………….373
43 – GEARBOX…………….377
Dropbox housing and cover…………….378
Transfer gearbox gears and shafts…………….382
Gear box housing with fitting parts…………….385
45 – PROPELLER SHAFT…………….388
Propeller shafts with fitting parts…………….389
Propeller shaft-[1744]…………….392
Propeller shaft…………….395
46 – FRONT AXLE; REAR AXLE…………….397
Driveshafts with assembly parts…………….398
Drive axle; front…………….403
Final drive; front…………….407
Differential lock…………….412
Hydraulic system…………….415
Drive axle; rear…………….418
Final drive; rear…………….423
49 – MISCELLANEOUS…………….428
Cooling system…………….429
5 – BRAKE…………….432
51 – WHEEL BRAKE…………….433
Brake…………….434
Disc brake …………….435
52 – HYDRAULIC BRAKE SYSTEM…………….438
Hydraulic brake system oil tank-foot brake valve-[1234]…………….439
Hydraulic brake system oil tank-foot brake valve…………….443
Hydraulic brake system footbrake valve – wheel…………….446
Tank with fitting parts…………….451
Pump with fitting parts…………….454
Relief valve with fitting parts-[1051]…………….457
Relief valve with fitting parts…………….461
Footbrake valve with mountings…………….464
Manometer with fitting parts…………….466
Pump…………….469
Pump …………….472
Valves-[838]…………….474
Footbrake valve CAB – 13278; (USA) CAB – 61641…………….478
Footbrake valve CAB 13279 – ; (USA) CAB 61642 – ; IRAN…………….481
Dual brake pedals 90730…………….484
55 – PARKING BRAKE…………….487
Parking brake…………….488
Disc brake…………….491
Hydraulic parking brake 91195; 91635…………….494
56 – COMPRESSED-AIR BRAKE…………….498
Compressed air equipment 91269; 91701…………….499
Air compressor 91269; 91701…………….503
Regulator 91269; 91701…………….507
Anti-freeze reservoir 91306…………….510
Anti-freeze reservoir…………….513
Air pressurized shafts 91352…………….516
6 – STEERING…………….519
64 – STEERING…………….520
Steering system-[324]…………….521
Steering system SER NO 6825 – 6889; (USA) SER NO 60502 – 60507…………….527
Steering system…………….531
Valves-[221]…………….535
Steering cylinder…………….538
Steering column with fitting parts…………….541
Steering unit…………….544
Valve body…………….547
Valves…………….550
Hydraulic cylinder …………….553
Hydraulic pump-[000]…………….556
Hydraulic pump-[5936]…………….559
Adjustable steering wheel (USA); 33230; 90667; 91310…………….562
Comfort drive control 91222…………….566
Control valve; comfort drive control 91222…………….570
Comfort drive control 91880…………….575
Valves 91880…………….579
Auxiliary steering system 90768…………….583
Pump unit 90768…………….586
Valves 90768…………….589
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT…………….592
71 – FRAME…………….593
Frame…………….594
Protecting plates…………….599
77 – WHEELS; TRACKS; TYRE; HUB; DRUM…………….603
Wheel 90734; 90796 – 90800; 91500 – 91503…………….604
Wheel 91505 – 6; 91508 – 91510; 91515; 98308; 98310 – 12…………….608
Wheel 98313 – 98314…………….612
Wheel 91289;91504;91507;91511;91516;92014;97874;99178;99851…………….615
Rim 91285…………….619
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE…………….622
81 – CAB; NAKED; CANOPY…………….623
Operator's cab…………….624
Cab body…………….627
82 – ENGINE HOOD; MUDGUARD; FOOT STEP…………….634
Engine hood…………….635
Side hatches…………….640
Radiator casing…………….644
Front- and rear mudguards…………….647
Full-coverage mudguard 90646…………….651
Dust guard 90930…………….655
Protection for fuel inlet 90971…………….658
83 – DOORS; HATCH; COVER PLATE; (all)…………….661
Door…………….662
Door 90883…………….666
84 – TRIM PART; OUTSIDE; GLASS; SEALING MOULDING…………….669
Glass panes and interior components…………….670
Windows CAB 8184-10852; (USA) CAB 60403-61170; IRAN CAB-50350…………….675
Windows CAB 10853 -; (USA) CAB 61171 – ; IRAN CAB 50351 – ……………..678
Ventilation pane STD USA; 98942…………….681
Rear view mirror…………….684
85 – CAB INTERIOR; UPHOLSTERY…………….686
Insulating matting…………….687
Operator seat with fitting parts CAB – 7420…………….691
Operator seat with fitting parts CAB 7421 – ; (USA); IRAN; 90683; 90883; 90939; 90940…………….694
Operator's seat-[4607]…………….698
Operator's seat…………….701
Driver's seat; air suspensioned; heated 91643-[4523]…………….704
Driver's seat; air suspensioned; heated 91643…………….707
Seat 90143…………….710
Comfort drive control; foldable arm rest 91222…………….713
Cdc-steering plate details 91880…………….716
86 – PROTECTIVE EQUIPMENT…………….719
Bottom-guard plates 91037…………….720
87 – AIR CONDITIONING UNIT…………….723
Radiator with fitting parts CAB – 7942; (USA) CAB – 60344…………….724
Radiator with fitting parts CAB 7943 – ; (USA) CAB 60345 – ; IRAN…………….728
Controls CAB – 7942; (USA) CAB – 60344…………….733
Controls CAB 7943-13753; (USA) CAB 60345-61715; IRAN CAB -50633…………….737
Controls CAB 13754 -; (USA) CAB 61716 – ; IRAN CAB 50634 -…………….741
Air ducts CAB – 7942; (USA) CAB – 60344…………….745
Air ducts CAB 7943 – ; (USA) CAB 60345 – ; IRAN…………….749
Fan CAB – 13753; (USA) CAB – 61715; IRAN CAB – 50633…………….753
Fan CAB 13754 – ; (USA) CAB 61716 – ; IRAN CAB 50634 -…………….756
Heating system; hoses…………….757
Air conditioning 90553; 91199…………….760
Air-compressor with fitting parts 90553; 91199…………….764
Condenser with fitting parts 90553; 91199…………….767
Evaporator with fitting parts 90553; 91199…………….771
Condenser 90553; 91199…………….775
Air compressor 90553; 91199…………….779
Extra air outlett cab ventilation 91251…………….782
88 – INTERIOR EQUIPMENT…………….784
Radio panel 99717 CAB – 9127; (USA) CAB – 60642…………….785
Radio panel 91305 CAB 9128 – ; (USA) CAB 60643 -…………….787
89 – MISCELLANEOUS…………….789
Tools…………….790
Sign plates and decals-[3600]…………….794
Sign plates and decals…………….799
Sign plates and decals USA…………….804
Slow moving vehicle sign 99592…………….809
Tyre-inflating equipment IRAN SER NO – 50613…………….812
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS…………….814
91 – WORKING HYDRAULIC; SERVO HYDRAULICS…………….815
Feed lines…………….817
Lifting system…………….823
Tilting system…………….827
Hydraulic tank…………….830
Hydraulic pump-[3233]…………….834
Hydraulic pump…………….837
Filter…………….840
Hydraulic cylinder lifting…………….843
Hydraulic cylinder tilting…………….846
Control valve SER NO -6679; USA SER NO -60478; IRAN SER NO -50362…………….849
Control valve SER NO 6680-; USA SER NO 60479-; IRAN SER NO 50363-…………….853
Relief valve…………….857
Servo-system feed lines SER NO -6889; USA SER NO -60507; IRAN SER NO -50362…………….860
Servo-system feed lines SER NO 6890 -; USA SER NO 60508 -; IRAN SER NO 50363-…………….865
Servo-system control lines…………….870
Servo-system servo valve…………….873
Assembly parts for servo valve…………….876
Lever lock STD USA…………….880
Lever lock 90522…………….883
003rd function 90609…………….885
Extra hydraulic equipment003rd hydraulic control 91273…………….889
003rd and 4th function 90608…………….893
Extra hydraulic equipment003rd and 4th function 91275; 91672…………….898
005th function 90819…………….903
Boom lowering system STD USA; 90746…………….906
Valves SER NO – 6294…………….909
Valves SER NO 6295 -…………….911
Single-acting lifting function 90773…………….914
Oil cooler…………….917
Attachment locking 91271; 91634…………….922
Automatic hose coupling (ahc) 91320 SER NO – 6551…………….926
Automatic hose coupling (ahc) 91320 SER NO 6552 -…………….929
Automatic hose coupling (ahc) 91320…………….932
Control cylinder 91320…………….935
Boom suspension system 91826…………….937
Valves 91826…………….941
92 – MECHANICAL EQUIPMENT_ATTACHMENT…………….944
Hydraulic attachment bracket 90423; 91541…………….945
Hydraulic cylinder…………….949
93 – MISCELLANEOUS…………….952
Engine heater 90678…………….953
94 – UNIT; LOAD HANDLING…………….956
Lifting unit 33312 SER NO – 6479; USA; IRAN…………….957
Lifting unit 33312 SER NO 6480 – ;…………….960
Links with fitting parts 33312 SER NO – 6479; USA; IRAN…………….964
Loading unit 33329…………….969
Lubricating kit 91639…………….973
Volvo BM L120B Parts Catalog…………….977
0 – GENERAL…………….978
03 – SPECIFICATIONS…………….979
Product identification plate…………….980
2 – ENGINE WITH MOUNTING AND EQUIPMENT…………….981
21 – ENGINE…………….982
Repair kits-[5845]…………….983
Engine with fitting parts…………….989
Cylinder head…………….992
Cylinder block…………….996
Crankshaft and related parts…………….999
Camshaft…………….1003
Timing gear casing and gears…………….1005
Engine mounting…………….1007
22 – LUBRICATING SYSTEM…………….1009
Lubricating oil system…………….1010
Oil pump…………….1013
Oil filter-[5503]…………….1015
Housing; oil filter…………….1017
Oil filler and dipstick-[5418]…………….1019
Oil cooler…………….1021
23 – FUEL SYSTEM…………….1023
Fuel system…………….1024
Fuel pipes; fuel injection pump – fuel filter…………….1026
Feed pump TD 71G…………….1028
Feed pump TD 73KBE; 92005…………….1030
Fuel filter…………….1032
Slurry separator…………….1034
Extra fuel filter 90656…………….1037
Fuel tank…………….1039
Injection pump with drive TD 71G; 92005 TD 73KBE…………….1041
Injection pump TD 71G…………….1044
Injection pump TD 73KBE; 92005…………….1048
Fuel lines; injectors…………….1051
Injector…………….1054
Centrifugal governor TD 71G; TD 73KBE…………….1057
Smoke limiter TD 71G…………….1062
Smoke limiter TD 73KBE; 92005…………….1064
25 – INLET & EXHAUST SYSTEM…………….1067
Inlet system…………….1068
Inlet manifold TD 73KBE; 92005…………….1070
Exhaust system…………….1072
Turbocharger with fitting parts…………….1074
Turbo charger; TD 71G…………….1076
Turbo charger TD 73KBE…………….1079
Air filter-[4543]…………….1081
Oil bath filter 92038…………….1083
Air filter 92038…………….1085
Pre cleaner cyclone type 90943…………….1088
Intercooler TD 73KBE; 92005…………….1090
26 – COOLING SYSTEM…………….1092
Cooling system-[4345]…………….1093
Cooling system oil cooler…………….1096
Radiator with fitting parts…………….1099
Water pump and thermostat housing…………….1102
Waterpump; assembly TD 73KBE; 92005. ENG – 62890…………….1105
Waterpump; assembly TD 73KBE; 92005. ENG 62891 -…………….1107
Water pump TD 73KBE; 92005; ENG – 62890…………….1109
Water pump TD 73KBE; 92005; ENG 62891 -…………….1111
Fan shroud STD USA…………….1113
Belt transmission…………….1115
Coolant filter 91876…………….1118
27 – ENGINE CONTROL…………….1120
Pedal…………….1121
Regulator control…………….1123
Hand throttle 91886…………….1125
Key turn engine stop…………….1127
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS…………….1129
31 – BATTERY…………….1130
Battery; assembly…………….1131
Battery box; assembly…………….1133
32 – ALTERNATOR; CHARGE REGULATOR…………….1135
Alternator with assembling details…………….1136
Alternator…………….1138
Brushles alternator 50a 91956…………….1140
Alternator 91956…………….1142
33 – STARTING SYSTEM…………….1144
Starter motor; mounting…………….1145
Starter motor…………….1146
Starter element with fitting parts 92027; 92005…………….1149
Pre-heater…………….1152
35 – LIGHTING…………….1154
Lighting; front…………….1155
Work lights; front 91847…………….1157
Attachment light 91994…………….1159
Lighting;rear…………….1161
License plate lamp 91993…………….1163
36 – OTHER ELECTRICAL EQUIPMENT…………….1164
Rotating beacon 91896…………….1165
Compressor horn…………….1167
Back-up warning unit 91935…………….1168
Windshield wiper; front…………….1170
Windshield wiper; rear…………….1172
Windshield washer Std. 91858…………….1174
Engine heater 92025…………….1176
37 – CABLE; FUSE; RELAY…………….1178
Electrical distribution box…………….1179
Cable harness; front…………….1182
Bucket automatic and lift automatic…………….1184
Cable harness for 3rd; 4th and 5th function 91978; 91980; 91981……………..1185
Attachment locking; 91992-[2811]…………….1187
Single-acting lifting function 91961…………….1189
Cable harnesses Cab-[2727]…………….1191
Cable harnesses Cab-[2702]…………….1194
Cable harnesses Cab…………….1196
Forward_reverse switch athydraulic controls 91944…………….1198
Cable harness for Cdc-steering 91916…………….1200
Boom suspension system 91965-[2537]…………….1202
Cable harness; air-suspensioned seat. 92075; 92196; 92380…………….1204
Parking brake alarm; 92079…………….1206
Cable harnesses; rear…………….1208
Cable harness; transmission…………….1211
Cable harness secondary steering system 91919…………….1213
Cable harness for air conditioning 91874…………….1215
Cable harness for air conditioning 92245…………….1217
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM…………….1219
Instruments panel…………….1220
Switch panel…………….1223
Sensor…………….1225
Relays; sensors and solenoid valves Reference list…………….1227
39 – MISCELLANEOUS…………….1230
Cable harness for radio 91936…………….1231
4 – POWER TRANSMISSION…………….1233
41 – CLUTCH; TORQUE CONVERTER…………….1234
Repair kits…………….1235
Torque converter-[1959]…………….1238
Torque converter…………….1240
42 – TRANSMISSION; HYDRAULIC CONTROL…………….1243
Hydraulic transmission with fitting parts…………….1244
Converter housing with assembly parts…………….1246
Clutch housing with fitting parts…………….1249
Clutches;gears and shafts…………….1251
Clutches forward and reverse 30870…………….1253
Clutches forward and reverse 30880…………….1255
Clutches 1st and 2nd speeds 30870…………….1257
Clutches 1st and 2nd speeds 30880…………….1259
Clutches 3rd and 4th speeds 30870…………….1261
Clutches 3rd and 4th speeds 30880…………….1263
Oil filler and dipstick…………….1265
Hydraulic lines and valve…………….1268
Gear selector valve 30870…………….1271
Gear selector valve 30880…………….1273
Valves 30870…………….1275
Valves 30880…………….1277
Transmission pump…………….1279
Valves-[1324]…………….1281
Safety valve 30880…………….1283
Pump drive…………….1284
43 – GEARBOX…………….1286
Dropbox housing and cover…………….1287
Transfer gearbox gears and shafts…………….1290
Gear box housing with fitting parts…………….1292
45 – PROPELLER SHAFT…………….1294
Propeller shafts with fitting parts…………….1295
Propeller shaft-[1034]…………….1297
Propeller shaft…………….1299
46 – FRONT AXLE; REAR AXLE…………….1300
Driveshafts with assembly parts…………….1301
Drive axle; front AH 60 I; AH 65 B…………….1303
Final gear front AH 60 I; AH 65 B…………….1306
Drive axle; rear Ah 53f; Ah 53h…………….1310
Drive axle; rear Ah 60k 92327…………….1313
Final gear; rear Ah 53f; Ah 53h; Ah 60k…………….1316
Differential lock…………….1319
Differential lock hydraulic line…………….1321
49 – MISCELLANEOUS…………….1323
Cooling system…………….1324
5 – BRAKE…………….1326
51 – WHEEL BRAKE…………….1327
Brake…………….1328
Disc brake-[0535]…………….1329
52 – HYDRAULIC BRAKE SYSTEM…………….1331
Brake hoses Tank – pump – footbrake valve Ser No – 8249……………..1332
Brake hoses Tank – pump – footbrake valve Ser No 8250 -; USA Ser No 60750 -…………….1334
Brake pipes Footbrake valve – front – and rear axle…………….1336
Foot brake valve with clutches…………….1339
Footbrake valve SER NO – 8747; SER NO – 60883 USA…………….1342
Footbrake valve SER NO 8748 – ; SER NO 60884 – USA…………….1344
Dual brake pedals 91925…………….1346
55 – PARKING BRAKE…………….1348
Parking brake…………….1349
Disc brake…………….1351
Hydraulic parking brake…………….1353
56 – COMPRESSED-AIR BRAKE…………….1356
Compressed air equipment 92173…………….1357
Air compressor 92173…………….1360
Regulator 92173…………….1363
Anti-freeze reservoir 92172-[0012]…………….1365
Anti-freeze reservoir 92172…………….1367
Air pressurized shafts 92233…………….1370
Brake shield…………….1372
6 – STEERING…………….1374
64 – STEERING…………….1375
Steering column assembly…………….1376
Adjustable steering wheel 92029; STD USA…………….1378
Steering system…………….1380
Steering unit…………….1383
Valve housing…………….1385
Hydraulic pump-[5642]…………….1386
Shift valve; assembly…………….1388
Shift valve…………….1390
Hydraulic cylinder Assembly…………….1392
Hydraulic cylinder-[5519]…………….1394
Auxiliary steering system 91919…………….1396
Sensor 91919…………….1398
Pump unit……………..1400
66 – LEVEL STEERING…………….1402
Comfort drive control 91916…………….1403
Valves 91916…………….1405
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT…………….1407
71 – FRAME…………….1408
Frame…………….1409
Protecting plates…………….1412
Bottom-guard plates 92567…………….1414
Protection for lighting 91583; 91584; 91585…………….1416
77 – WHEELS; TRACKS; TYRE; HUB; DRUM…………….1418
Wheels 23;5 – 25_16-[5101]…………….1419
Wheels 23;5 – 25_16…………….1421
Rim. 91285; 20;5 – 25…………….1423
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE…………….1425
81 – CAB; NAKED; CANOPY…………….1426
Cab body…………….1427
Operator's cab…………….1430
82 – ENGINE HOOD; MUDGUARD; FOOT STEP…………….1432
Engine cover…………….1433
Side hatches; front…………….1436
Side hatches; rear…………….1439
Radiator casing…………….1442
Mud guards SER NO – 9484; SER NO – 61710 USA…………….1446
Mud guards SER NO 9485 -; SER NO 61711 – USA…………….1448
Extended fenders 91963…………….1450
Extended fenders 92329…………….1452
Foot step…………….1454
83 – DOORS; HATCH; COVER PLATE; (all)…………….1456
Door Mounting…………….1457
Door…………….1459
84 – TRIM PART; OUTSIDE; GLASS; SEALING MOULDING…………….1462
Glass panes…………….1463
Sliding window 92028; 92194…………….1465
85 – CAB INTERIOR; UPHOLSTERY…………….1467
Interior components…………….1468
Insulating matting…………….1470
Driver's seat; assembly…………….1473
Operator's seat; Air suspensioned Kab 92382…………….1475
Operator's seat; heated; air suspensioned. 92075; 92196-[4221]…………….1477
Driver's seat; air suspensioned Isri 92404; 92405…………….1479
Operator's seat Kab 92381…………….1481
Driver's seat Heated. 91950; STD USA…………….1483
Operator's seat Be-ge 92379…………….1485
Operator's seat; Heated; Air Suspensioned. 92075; 92196…………….1487
Operator's seat; heated; air suspensioned. 92380…………….1489
Operator seat Isri 92403…………….1491
Instructor's seat 91988…………….1493
Comfort drive control; foldable arm rest. 91916…………….1495
Control lever. 91916…………….1497
87 – AIR CONDITIONING UNIT…………….1500
Heating system…………….1501
Air filter…………….1502
Air ducts…………….1504
Fan…………….1506
Radiator and control…………….1507
Compressor with fitting parts. Cooling agent R12 91874…………….1510
Compressor for cooling agent R134a with fitting parts. 92245…………….1512
Condenser with fitting parts. Cooling agent R12 91874…………….1514
Condenser for cooling agent R134a with fitting parts. 92245…………….1516
Evaporator with fitting parts. Cooling agent R12 91874…………….1518
Evaporator for cooling agent R134a with fitting parts. 92245…………….1520
88 – INTERIOR EQUIPMENT…………….1522
Instrument panel…………….1523
Radio bracket 91936…………….1525
89 – MISCELLANEOUS…………….1527
Toolbox 91837…………….1528
Tools 98192; 99432…………….1530
Sign plates and decals-[3303]…………….1532
Sign plates and decals…………….1535
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS…………….1538
91 – WORKING HYDRAULIC; SERVO HYDRAULICS…………….1539
Hydraulic system Suction line…………….1540
Hydraulic system Feed line…………….1542
Hydraulic system Return line…………….1544
Hydraulic system Lift function…………….1546
Hydraulic system Tilt function…………….1548
Hydraulic tank…………….1550
Oil filter…………….1552
Hydraulic oil cooler…………….1554
Hydraulic valve Assembly…………….1556
Hydraulic valve…………….1558
Valves…………….1561
Hydraulic – oil pump Assembly…………….1563
Hydraulic pump…………….1564
Servo – hydraulic…………….1566
Servo valve; assembly…………….1569
Servo valve…………….1572
Attachment locking; 91992…………….1574
Extra hydraulic equipment3rd hydraulic control 91978…………….1576
Extra hydraulic equipment3rd and 4th function 91980…………….1579
Extra hydraulic equipment5th function. 91981…………….1582
Valves 91980…………….1584
Automatic hose coupling (ahc). 91320…………….1586
Automatic hose coupling; hydraulic clutch. 91320…………….1589
Control cylinder; 91320…………….1592
Boom suspension system 91965…………….1594
Valve; 91965…………….1597
Boom lowering system; 90746…………….1600
Single acting lifting function 91961…………….1602
92 – MECHANICAL EQUIPMENT_ATTACHMENT…………….1604
Hydraulic attachment bracket 90423; 91541…………….1605
Hydraulic cylinder-[2205]…………….1608
Hydraulic cylinder…………….1610
94 – UNIT; LOAD HANDLING…………….1612
Lifting unit…………….1613
Links with fitting parts…………….1615
Hydraulic cylinder Lifting…………….1618
Hydraulic cylinder Tilting…………….1620
99 – MISCELLANEOUS…………….1622
Extended lubepoints for loader linkage. 91639…………….1623
Volvo BM L120B Wheel Loaders Service Repair Manual…………….1625
0 – GENERAL…………….1626
00 – DESCRIPTION; COMPLETE MACHINE…………….1627
Description…………….1628
Product Identification Plates…………….1629
03 – SPECIFICATIONS…………….1630
Brakes; L90B…………….1631
Brakes; L120B…………….1633
Capacities…………….1635
Electrical system; L90B…………….1636
Electrical system; L120B…………….1638
Engine; L90B…………….1640
Engine; L120B…………….1644
Hydraulic system; L90B…………….1648
Hydraulic system; L120B…………….1649
Power transmission; L90B…………….1651
Power transmission; L120B…………….1653
Servo system; L90B…………….1655
Servo system; L120B…………….1656
Steering system; L90B…………….1657
Steering system; L120B…………….1659
Tightening torques…………….1661
VOLVO BM standard tightening torques…………….1664
Weights; (approx.)…………….1666
07 – STANDARD TIME…………….1667
Time Guide…………….1668
08 – TOOL…………….1678
E-Tools…………….1679
1 – STANDARD PARTS; SERVICE…………….1686
17 – SERVICE…………….1687
Charging of batteries …………….1688
Cleanliness brake and hydraulic systems…………….1689
Electric welding…………….1690
Repairing hydraulic systems…………….1691
Towing the machine…………….1692
19 – GENERAL…………….1693
A few simple rules for batteries_58-34…………….1694
A few simple rules for batteries…………….1695
A few simple rules of safety…………….1696
A few simple rules when inflating tyres…………….1702
A few simple rules when servicing…………….1703
Charging batteries…………….1708
Danger in connection with polymer materials…………….1709
Measures to prevent a fire…………….1711
Refrigerant in air-conditioning units…………….1714
Safety concerns everybody!…………….1716
Service position…………….1717
Starting with booster batteries…………….1719
2 – ENGINE WITH MOUNTING AND EQUIPMENT…………….1720
21 – ENGINE…………….1721
Checking function; engine…………….1722
Engine; fitting…………….1723
Engine; removing…………….1726
Specifications; L90B_50-38…………….1730
Specifications; L120B_50-12…………….1732
Specifications_49-47…………….1734
Specifications_49-02…………….1735
22 – LUBRICATING SYSTEM…………….1736
Specifications; L90B_47-57…………….1737
Specifications; L120B_47-12…………….1738
23 – FUEL SYSTEM…………….1739
Checking rotational speed with frequency meter…………….1740
Fuel system; bleeding…………….1742
Idling speed; checking and adjusting…………….1744
Injection timing; checking and adjusting…………….1746
Specifications; L90B_43-46…………….1751
Specifications; L120B_43-21…………….1752
Specifications; L90B_42-24…………….1753
Specifications; L120B_41-59…………….1754
Specifications; L90B_41-14…………….1755
Specifications; L120B_40-49…………….1756
Specifications; L90B_39-59…………….1757
Specifications; L120B_39-33…………….1758
25 – INLET & EXHAUST SYSTEM…………….1759
Specifications; L90B_38-29…………….1760
Specifications; L120B_38-03…………….1761
Specifications_37-38…………….1762
Specifications_36-48…………….1763
26 – COOLING SYSTEM…………….1764
Specifications; L90B …………….1765
Specifications; L120B …………….1766
Radiator; changing…………….1767
Specifications_33-57…………….1769
Specifications_33-32…………….1770
3 – ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS…………….1771
30 – GENERAL…………….1772
Description …………….1773
Special instructions when working on the electrical systems…………….1774
Specifications_ …………….1775
31 – BATTERY…………….1776
Charging of batteries…………….1777
Specifications_ …………….1778
32 – ALTERNATOR; CHARGE REGULATOR…………….1779
Specifications_29-06…………….1780
33 – STARTING SYSTEM…………….1781
Specifications_ …………….1782
Preheating; description of function…………….1783
Starting engine; description of function…………….1784
Stop solenoid; description of function…………….1785
35 – LIGHTING…………….1786
Specifications …………….1787
Headlights; adjusting…………….1788
36 – OTHER ELECTRICAL EQUIPMENT…………….1789
Code key for connectors (connected to the circuit board)…………….1790
Code key for connectors (others)…………….1803
Code key for diodes…………….1821
Control unit function; general description…………….1823
Emergency operational; electrical…………….1826
Functions which are not included in the central warning…………….1828
Monitored functions…………….1829
Other electrical functions (controlled by the control unit)…………….1831
Units connected to the control unit…………….1833
37 – CABLE; FUSE; RELAY…………….1835
Codes used in wiring diagrams…………….1837
Component location; circuit 11–110…………….1844
Component location; circuit 21–210…………….1847
Component location; circuit 31–310…………….1850
Component location; circuit 41–410…………….1853
Component location; circuit 51–510…………….1856
Component location; circuit 61–610…………….1859
Component location; circuit 71–79…………….1862
Component location; circuit 81–810…………….1865
Component location; circuit 91–97…………….1868
Component location; circuit 101–108…………….1871
Component location; circuit 111–117…………….1874
Component location; circuit 121–129…………….1875
Component location; circuit 131–1310…………….1878
Component location; circuit 141–147…………….1881
Component location; circuit 151–155…………….1884
Component location; circuit 161–168…………….1887
Component location; circuit 171–177…………….1888
Component location; circuit 181–187…………….1891
Component location; circuit 191–197…………….1894
Component location; circuit 201–2010…………….1897
Component location; circuit 211–2110…………….1900
Component location; circuit 221–229…………….1903
Explanations to wiring diagrams…………….1906
List of circuits…………….1911
Wiring diagram; circuit 11–110…………….1915
Wiring diagram; circuit 21–210…………….1918
Wiring diagram; circuit 31–310…………….1921
Wiring diagram; circuit 41–410…………….1925
Wiring diagram; circuit 51–510…………….1927
Wiring diagram; circuit 61–610…………….1931
Wiring diagram; circuit 71–79…………….1933
Wiring diagram; circuit 81–810…………….1935
Wiring diagram; circuit 91–97…………….1938
Wiring diagram; circuit 101–108…………….1940
Wiring diagram; circuit 111–117…………….1942
Wiring diagram; circuit 121–129…………….1944
Wiring diagram; circuit 131–1310…………….1946
Wiring diagram; circuit 141–147…………….1949
Wiring diagram; circuit 151–155…………….1951
Wiring diagram; circuit 161–168…………….1953
Wiring diagram; circuit 171–177…………….1955
Wiring diagram; circuit 181–187…………….1957
Wiring diagram; circuit 191–197…………….1960
Wiring diagram; circuit 201–2010…………….1962
Wiring diagram; circuit 211–2110…………….1964
Wiring diagram; circuit 221–229…………….1966
Circuit board…………….1968
Electrical distribution box…………….1972
Fuses…………….1973
Relays…………….1975
Specifications_ …………….1977
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM…………….1978
Centre instrument panel (control lamp panel)…………….1979
Front left panel…………….1980
Front right panel…………….1982
Instruments and controls…………….1983
Other controls…………….1986
Right instrument panel…………….1989
Contronic System…………….1992
Service Contronic Display Unit…………….1994
4 – POWER TRANSMISSION…………….2001
40 – GENERAL…………….2002
APS (Automatic Power Shift)…………….2003
Specifications; L90B_00-47…………….2008
Specifications; L120B_00-22…………….2009
41 – CLUTCH; TORQUE CONVERTER…………….2010
Specifications; L90B_59-34…………….2011
Specifications; L120B_59-09…………….2012
42 – TRANSMISSION; HYDRAULIC CONTROL…………….2013
Specifications; L90B_58-21…………….2014
Specifications; L120B_57-51…………….2015
Gear selector valve_57-26…………….2016
Gear selector valve…………….2019
Gear selector valve _ transmission…………….2022
Oil Pressures; checking (all)…………….2027
Specifications_55-32…………….2033
Transmission; fault tracing…………….2034
Transmission; fitting (together with engine)…………….2035
Transmission; removing (together with engine)…………….2039
Specifications_54-01…………….2045
43 – GEARBOX…………….2046
Specifications_53-07…………….2047
45 – PROPELLER SHAFT…………….2048
Specifications_52-19…………….2049
46 – FRONT AXLE; REAR AXLE…………….2050
Differential housing; changing wear ring…………….2051
Specifications_50-52…………….2052
Specifications; L90B_50-09…………….2053
Specifications; L120B_49-44…………….2054
Specifications; L90B_48-48…………….2055
Specifications; L120B_48-24…………….2056
Differential lock; front; adjusting…………….2057
Specifications_…………….2060
5 – BRAKE…………….2061
50 – GENERAL…………….2062
Specifications; L90B_ …………….2063
Specifications; L120B_…………….2064
51 – WHEEL BRAKE…………….2065
Description_…………….2066
Function_…………….2069
Specifications_…………….2075
52 – HYDRAULIC BRAKE SYSTEM…………….2076
Adjusting brake pedal angle…………….2077
Brake system; checking and adjusting of pressure in circuit…………….2078
Brake system; checking and adjusting unloading pressure…………….2080
Brake system; checking function…………….2082
Hydraulic diagram; L90B…………….2085
Hydraulic diagram; L120B…………….2087
Brake valve…………….2089
Specifications; L90B_……………..2092
Specifications; L120B_……………..2093
Accumulator; checking (Removed)…………….2094
Specifications; L90B_…………….2097
Specifications; L120B_…………….2098
55 – PARKING BRAKE…………….2099
Description_…………….2100
Specifications_…………….2101
Basic setting; checking and adjusting…………….2102
Hydraulically controlled…………….2104
6 – STEERING…………….2105
60 – GENERAL…………….2106
Description; L90B…………….2107
Description; L120B…………….2108
64 – STEERING…………….2109
Specifications; L90B_ …………….2110
Specifications; L120B_ …………….2111
Hydraulic diagram; basic machine (L90B)…………….2112
Hydraulic diagram; basic machine (L120B)…………….2115
Hydraulic diagram; basic machine ; lever steering (CDC); secondary steering (L90B)…………….2118
Hydraulic diagram; basic machine ; lever steering (CDC); secondary steering (L120B)…………….2120
Hydraulic diagram; basic machine; lever steering (CDC) (L90B)…………….2122
Hydraulic diagram; basic machine; lever steering (CDC) (L120B)…………….2125
Hydraulic diagram; basic machine; secondary steering (L90B)…………….2128
Hydraulic diagram; basic machine; secondary steering (L120B)…………….2131
Pressure _ flow compensator; description; L90B…………….2134
Pressure _ flow compensator; description; L120B…………….2139
Pump; description; L90B…………….2145
Pump; description; L120B…………….2147
Shift valve; L120B…………….2149
Specifications; L90B_…………….2153
Specifications; L120B_…………….2154
Stand-by pressure; checking and adjusting…………….2156
Steering cylinder; component location…………….2158
Steering valve; description; L90B…………….2159
Steering valve; description; L120B…………….2160
Steering valve; L120B…………….2161
Working pressure checking and adjusting…………….2163
Description_…………….2165
Function…………….2169
66 – LEVEL STEERING…………….2172
Adjusting steering speed; lever steering…………….2173
Checking the output voltage from steering lever…………….2174
Control valve; lever steering (CDC)…………….2177
Description_…………….2180
Description of hydraulic system…………….2184
Hydraulic diagram; basic machine; lever steering (CDC)…………….2185
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT…………….2188
71 – FRAME…………….2189
General description…………….2190
Specifications; L90B_16-15…………….2191
Specifications; L120B_15-51…………….2192
Specifications……………..2193
Specifications_…………….2194
74 – FRAME LINK…………….2195
Specifications……………..2196
75 – AXLE SUSPENSION…………….2197
Rear axle suspension…………….2198
Rear axle suspension; L90B…………….2199
Rear axle suspension; L120B…………….2201
Adjusting the rear rear-axle bridge axial clearance; L90B…………….2202
Adjusting the rear rear-axle bridge axial clearance; L120B…………….2203
Front rear-axle bridge; complete; L90B…………….2204
Front rear-axle bridge; complete; L120B…………….2205
77 – WHEELS; TRACKS; TYRE; HUB; DRUM…………….2206
Specifications…………….2207
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE…………….2208
81 – CAB; NAKED; CANOPY…………….2209
Specifications……………..2210
87 – AIR CONDITIONING UNIT…………….2211
Description_…………….2212
Electrical system; description of function…………….2215
AC safety; description of function…………….2218
Description…………….2221
Refrigerant for all air conditioning…………….2225
Specifications…………….2226
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS…………….2227
91 – WORKING HYDRAULIC; SERVO HYDRAULICS…………….2228
Adjusting automatic lifting and tilting…………….2230
Automatic lifting and tilting and floating position…………….2232
Detent function floating position and floating position…………….2234
Detent function lifting _ automatic lifting (boom kick-out)…………….2236
Hydraulic diagram; detent function floating position and floating position…………….2237
Hydraulic diagrams; L90B…………….2240
Hydraulic diagrams; L120B…………….2249
Specifications; L90B……………..2258
Specifications; L120B ……………..2259
Working hydraulics; description…………….2260
Specifications……………..2263
Back-up valve; checking opening pressure…………….2264
Control valve; functions…………….2265
Shock and anti-cavitation functions…………….2270
Shock valve; tilting function; checking and adjusting…………….2272
Specifications; L90B_…………….2278
Specifications; L120B_…………….2279
Changing or repairing hydraulic pumps…………….2280
Hydraulic oil pump; checking and adjusting unloading pressure (Applies only to L120B)…………….2281
Hydraulic oil pump; checking and adjusting working pressure…………….2284
Specifications; L90B.1…………….2286
Specifications; L120B……………..2287
Servo pressure; checking and adjusting (AHC)…………….2288
Servo pressure; checking and adjusting (not AHC)…………….2292
Servo pressure; checking by spool in control valve…………….2294
Servo valve; adjusting controls…………….2296
Servo valve; function…………….2300
Specifications…………….2304
AHC _ Separate attachment locking…………….2305
AHC automatic connection of attachments with hydraulic functions…………….2310
Sequence valves; checking and adjusting opening pressure…………….2312
94 – UNIT; LOAD HANDLING…………….2316
Lifting cylinder; L90B…………….2317
Lifting cylinder; L120B…………….2318
Specifications; L90B…………….2319
Specifications; L120B…………….2320
Tilting cylinder; L90B _ L120B…………….2321
99 – MISCELLANEOUS…………….2322
Accumulator; filling with gas…………….2323
Boom Suspension System…………….2325
Boom Suspension System; electrical system…………….2331
Boom Suspension System; hydraulic system…………….2333
Checking function; boom suspension system…………….2338
Valve block; boom suspension system…………….2339
Volvo BM L120 / L120B Wheel Loaders Parts Manual