Injectors, Description: Service Information

Service Information
Document Title: Function Group: Information Type: Date:

Injectors, description 237 Service Information 2021-05-17
Profile:
L120E Volvo
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Injectors, description
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Model Production site Serial number start Serial number stop
L120E Volvo Arvika 16001 19668
L120E Volvo Asheville 64001 65999
L120E Volvo Pederneiras 70701 70701
The lower sleeve on the injector with injector nozzle is shaped to give even fuel spray pattern, despite the angle of the injector,
and thus the injector nozzle has to face in one way only.
The injector nozzle has seven holes.
Figure 1
Service Information

Injectors, specifications 237 Service Information 2021-05-17
Profile:
L120E Volvo
Injectors, specifications

Injectors
Type Multi-hole nozzle (7 holes)
Opening pressure 25 MPa (250 bar) (3526 psi)
Order of injection 1-5-3-6-2-4
Service Information

Fuel feed pressure, checking 233 Service Information 2021-05-17
Profile:
L120E Volvo
Fuel feed pressure, checking


Op nbr 23304
Pressure gauge 11 666 017

Hose 11 666 037
Nipple 9993720
1. Park the machine in the service position.
2. Raise the left hood panel.
3. Remove the plug by the fuel filter and install nipple 9993720 and hose and gauge.
Figure 1
1. 9993720 Nipple
4. Start the engine and read off the fuel feed pressure at 1500 rpm.
Fuel feed pressure: min. 280 kPa (2.8 bar) (40.6 psi)
If the recorded pressure is too low, the fuel filter may be clogged. Replace the filter and check the fuel feed pressure again.
If the pressure still is too low this may be due to faulty overflow valve, fuel pump or fuel supply.
Check the fuel feed pump and that fuel can reach the pump.
Service Information

Fuel feed pump, description 233 Service Information 2021-05-17
Profile:
L120E Volvo
Fuel feed pump, description


L120E Volvo
The fuel feed pump is designed as a rotor pump and is driven by a Vee-belt.
The non-return valve (2) prevents the fuel from draining back to the tank. This facilitates re-starting the engine.
If the fuel lines have been run dry of fuel, the fuel system should be filled and bled with the hand pump located on the primary
filter housing. The non-return valve (2) opens and allows fuel to circulate in the entire circuit. In this way, the unit pumps are
supplied with fuel free from air.
Figure 1
Service Information

Fuel feed pump, 233 Service Information 2021-05-17
specifications
Profile:
L120E Volvo
Fuel feed pump, specifications


Fuel feed pump

Type Rotor pump
Feed pressure 350–500 kPa (3.5–5.0 bar) (50.7–72.5 psi)
Service Information

Fuel system, bleeding 230 Service Information 2021-05-17
Profile:
L120E Volvo
Fuel system, bleeding


NOTE!
Avoid unnecessary fuel spills, collect any fuel in a container.
Op nbr 233-001
Total procedure time (hr): 0.40
1.
Open the bleeder screw (1) on the primary filter.

Pump with the hand pump (2) on the primary filter until fuel free from air flows out.
Close the bleeder screw.
Then, pump another few strokes with the hand pump.
Start the engine and let it run at high idle for approx. 10 minutes to bleed out any remaining air in the system.
Figure 1
NOTE!
Check for leaks after starting.
Service Information

Fuel system, description 230 Service Information 2021-05-17
Profile:
L120E Volvo
Fuel system, description


General
The engine has an injection system where the fuel is injected into the combustion chambers via separate injection pumps one for
each cylinder.
The fuel is delivered from the tank via the primary filter by the fuel feed pump via the secondary filter to the supply channel for
the unit pumps.
From the unit pumps, the fuel is delivered through the pressure (delivery) pipes to the injectors.
Return fuel from the unit pumps passes via a channel in the cylinder block to the overflow valve, which is placed in the outlet
from the cylinder head fuel channel.
The overflow valve controls the feed pressure in the fuel system.
The high feed pressure ensures filling of the unit pumps.
The fuel pump has a very high flow and excess fuel helps to cool the unit pumps.
After the overflow valve, the fuel passes via a cooler to the tank.
Figure 1
Service Information

Component list 11: sensors 370 Service Information 2021-05-17
Profile:
L120E Volvo
Component list 11: sensors


L120E Volvo
Designation Wiring diagram Circuit no. Sensor type Function
SE201 4 2.040 Frequency Engine rpm for vehicle control unit V-ECU
SE207 4 2.100 Level Fuel level
SE210 5 2.130 Temperature Coolant temperature, outlet radiator
SE211 5 2.130 Frequency Fan speed
SE213 5 2.150 Level Engine oil level
SE214 27 2.210 Position Throttle pedal
SE301 8 3.270–3.280 Pressure Brake lights

SE302 7 3.140 Mechanical Interior lighting
SE401 10 4.120 Pressure Filter indicator transmission
SE402 10 4.130 Frequency Turbine speed
SE403 10 4.140 Frequency Output rpm transmission (for travel speed)
SE405 12 4.180 Pressure Transmission oil pressure
SE406 12 4.190 Temperature Transmission oil temperature

SE408 12 4.220 Mechanical Differential lock
SE410 13 4.230 Temperature Axle oil temperature, front axle
SE411 13 4.240 Temperature Axle oil temperature, rear axle
SE413 13 4.310 Level Transmission oil level
SE501 15B 5.010 Pressure Output brake pressure/ Transmission
disengagement
SE502 15B 5.020 Pressure Low brake pressure

SE503 15B 5.045 Pressure Parking brake
SE503 32 8.230 Pressure Parking brake with lift-truck safety norms
SE504 15B 5.050 Pressure Brake pressure charging
SE601 16 6.010 Mechanical Secondary steering differential pressure[T1]i
SE602 16 6.010 Pressure Secondary steering, steering pressure
SE603 17 6.020 Mechanical Joystick Comfort Drive Control (CDC)⁽ᵃ⁾
SE606 16 6.010 Pressure Automatic test of secondary steering
SE803 19 8.090 Temperature Air conditioning (AC), thermostat⁽ᵃ⁾
SE804 19.33 8.090, 8.100 Pressure Climate control system, pressure monitor⁽ᵃ⁾
SE805 26 — Pressure Central lubrication⁽ᵃ⁾
SE806 32 8.230 Mechanical Seat sensor rider truck standard⁽ᵃ⁾
SE807 20 8.250 Temperature Ambient temperature
[T1]Optional equipment
Designation Wiring diagram Circuit no. Sensor type Function

SE808 33 8.100 Temperature Temperature evaporator[T1]i
SE809 33 8.100 Temperature Temperature ambient air⁽ᵃ⁾
SE810 33 8.100 Temperature Temperature after heating coil⁽ᵃ⁾
SE811 33 8.100 Temperature Temperature cab⁽ᵃ⁾
SE901 21, 21B, 21C 9.010 Inductive Bucket kickout
SE902 21, 21B, 21C 9.020 Inductive Boom kickout
SE906 23 9.120 Temp. / Level Hydraulic oil tank, temperature and level
SE922 35 — Inductive Lift arm position⁽ᵃ⁾
SE932 35 — Mechanical Hold position for automatic lift arm lowering⁽ᵃ⁾
SE2202 28 2.310 Temperature Engine oil temperature (D7E)
SE2203 29 2.320 Pressure Engine oil pressure
SE2205 28 2.150 Level Engine oil level
SE2301 29 2.340 Pressure Fuel pressure
SE2302 28 2.490 Level Water in fuel
SE2306 29 2.330 Temperature Fuel temperature
SE2309 29 2.500 Pressure Fuel pressure Common Rail
SE2501 28 2.260 Temperature Temperature induction air
SE2502 28 2.260 Pressure monitor Air filter monitor

SE2507 29 2.290 Temperature Charge-air temperature
SE2508 29 2.300 Pressure Boost pressure
SE2603 28 2.250 Level Coolant level
SE2606 29 2.280 Temperature Coolant temperature
SE2701 28 2.230 Frequency Engine rpm/ flywheel position for E-ECU
SE2703 28 2.240 Frequency Camshaft speed
Figure 1
Component position: Sensors
Figure 2
Component position: Sensors
Figure 3
Component position: Sensors on engine D7D
Figure 4
Component position: Sensors on engine D7E
Service Information

Component list 12: switches 370 Service Information 2021-05-17
Profile:
L120E Volvo
Component list 12: switches


L120E Volvo
Designation Wiring diagram Circuit no. Function
SW100 1, 102 — Battery disconnect switch

SW101 1, 102 — Ignition
SW101 3 2.010 Ignition
SW101 19, 33 8.090, 8.100 Ignition
SW102 102 — Emergency stop, electrically controlled battery disconnect
switch[T1]i
SW201 3 2.020 Preheating
SW301 6 3.010–3.130 Parking lights and headlights

SW302 6 3.090–3.130 High and low beams, function selector
SW303 7 3.150–3.190 Work lights front, cab and front fender
SW303 103 3.165 Work lights front, cab and front fender⁽ᵃ⁾
SW304 7 3.200–3.240 Work lights rear, cab and radiator casing
SW304 101 3.200 Work lights rear, cab and radiator casing⁽ᵃ⁾
SW305 8 3.260 Rotating warning beacon

SW306 8 3.285–3.330 Hazard flashers
SW307 8 3.300–3.330 Direction indicators right and left
SW401B, C 9, 9B 4.010–4.020 Shifting, kick-down
SW402 9, 9B 4.030 Forward/Reverse, steering column
SW403 9 4.040 Activation Forward/Reverse, lever carrier
SW403 9B 4.040 Activation Forward/Reverse, single lever⁽ᵃ⁾

SW404 9 4.050 Forward/Reverse, lever carrier
SW405 9 4.060 Kick-down, lever carrier
SW405 9B 4.060 Kick-down, single lever⁽ᵃ⁾
SW406 9 4.070 Engine retarder, lever carrier
SW406 9B 4.070 Engine brake, single lever⁽ᵃ⁾
SW407 17 4.080 Armrest Comfort Drive Control (CDC)⁽ᵃ⁾
SW408 17 4.090 Activation Comfort Drive Control (CDC)⁽ᵃ⁾
SW409 17 4.100 Forward/Reverse, Comfort Drive Control (CDC)⁽ᵃ⁾
SW410 17 4.110 Kick-down Comfort Drive Control (CDC)⁽ᵃ⁾
SW411 11 4.170 Transmission disengagement
SW412 12 4.210 Mode selector
Designation Wiring diagram Circuit no. Function

SW414 12 4.210 Differential lock
SW416 9B 4.050 Neutral/Forward/Reverse, single lever[T1]i
SW417 11 4.260 Fully automatic⁽ᵃ⁾
(Replaces SW411)
SW501 15B 5.045 Parking brake
SW501 32 5.045 Parking brake with lift-truck safety norms
SW601 16 6.010 Secondary steering test
SW801A 18 8.010–8.025 Front wiper

SW801B 18 8.025 Front washer
SW801C 18 8.030 Horn
SW802 18 8.030 Horn
SW803 18 8.040 Wiper rear⁽ᵃ⁾
SW804 18 8.050 Washer rear⁽ᵃ⁾
SW805 19, 33 8.080 Cab fan

SW806 19, 33 8.090, 8.100 Air conditioning⁽ᵃ⁾
SW807 25 — Keypad
SW808 26 — Central lubrication system⁽ᵃ⁾
SW810 33 8.100 Dehumidification position, forced ATC⁽ᵃ⁾
SW811 34 8.140 Electrically heated rear-view mirrors⁽ᵃ⁾
SW901 21, 21B, 21C 9.010 Bucket kickout

SW902 21, 21B, 21C 9.020 Boom kickout
SW903 21, 21B, 21C 9.050 Hold solenoid float position
SW904 21 9.040 Attachment lock
SW909 23 9.090 Boom Suspension System, single-acting lifting function
SW910 21 9.030 Attachment change (increased pressure)
SW911 21B 9.060 Electric lever lock, machine with 4th hydraulic function
SW913 22 9.310 Emergency stop 3rd hydraulic function
SW918 22 9.310 Hold function 3rd hydraulic function
SW920 21C 9.065 Single lever, lever lock-out
SW925 23 9.085 Boom Suspension System, activation and function selection
SW933 35 — Activation return-to-dig and float mode. (Replaces SW903.)
Figure 1
Switches a. See component list 8.
Service Information

Wiring diagram 2 370 Service Information 2021-05-17
Profile:
L120E Volvo
Wiring diagram 2

L120E Volvo
Feeds E-ECU, I-ECU, V-ECU
Production location ARV ASH PED

Serial no. –19678 –63999 –71399
Figure 1

Serial no. 64000–66000
Figure 2

Serial no. 19801– 66001– 71401–
Figure 3
Service Information

Profile:
L120E Volvo
Wiring diagram 1

L120E Volvo
Main diagram
Figure 1
a. SW101, connection P and 19 not used.
Service Information

Profile:
L120E Volvo
Wiring diagram 28

L120E Volvo
Sensors connected to E-ECU

Serial no. -2165 -60999 -70399
Figure 1

Serial no. 2201– 61001– 70401–
Figure 2
Service Information

Electrical system, 300 Service Information 2021-05-17
description
Profile:
L120E Volvo
Electrical system, description


L120E Volvo
The machine has a 24 V electrical system with two 12 volt batteries located on each side of the rear frame behind the rear
wheels.
The battery disconnect switch is located under the radiator casing.
Voltage feed takes place via a fuse box located in the engine compartment. The fuse box contains main fuse as well as fuses for
preheating coil and secondary steering pump.
Relays and fuses are placed in the electrical distribution box behind the operator's seat and are accessible when the cover is
opened. On the inside of the cover, a decal showing which current-consuming device is connected to respective relays and fuses.
The relays in the electrical distribution box are interchangeable.
The components are marked according to function group. The first digit in the marking, i.e. SE201, indicates that the component
belongs to engine (group 2). Other digits are sequential numbers. There are also components with a four-digit designation, i.e.
SE2203. The first two digits indicate function group and the other indicate sequential numbers.
NOTE!
For working on the electrical system, follow the instructions in section Electrical system, work instructions.
Figure 1
Position
1. Battery disconnect switch
2. Battery
3. Fuse box
4. Electrical distribution box
Figure 2
Principle illustration of electrical system
Service Information

Electrical symbols and 370 Service Information 2021-05-17
designations
Profile:
L120E Volvo
Electrical symbols and designations


L120E Volvo
Designation Symbol Explanation

ALT Alternator with charging regulator
BA Battery
C Capacitor
CU Electronic unit
DI Diode
E-ECU Engine control unit
FC Fuse
FH
FU
I-ECU Instrument control unit
IM Instrument, i.e. hour meter
LA Light, fixed light

Light, flashing light
LC Control light, fixed light
LC Control light, flashing light
MA Solenoid valve or PWM-valve for control of oil
MO Electric motor
Starter motor
R Resistor
Rheostat
RF Flasher relay
RE Relay:
No control current on 86–85 contact position 30–87A (Permitted
load 10A)
Control current on 86–85 contact position 30–87 (Permitted load
20A)
RT Time relay
SA Audible signal
Audible signal
SE Frequency sensor, i.e. rpm transmission
Inductive sensor
Level sensor
Temperature sensor
Pressure sensor
Pressure monitor
Mechanical monitor
SW Single terminal switch with manual on and off, i.e. activation of air
conditioning
Single terminal switch with manual on and automatic off, i.e. horn
Double terminal switch with manual on and off with lock-out, e.g.,
SW911
V-ECU Vehicle control unit

Ground connection
Ground connection engine block
Shielded cable
Service Information

Engine ECU, removing 237 Service Information 2021-05-17
Profile:
L120E Volvo
Engine ECU, removing


Op nbr
2. Turn off the electric power with the battery disconnect switch.
3. Raise the radiator hood.
Figure 1
Removing
4. Remove the protective plate (1) for the engine ECU. Disconnect connector EAEB from engine ECU (2). Remove bolts (3).
Figure 2
5. Remove the engine ECU.
Installing
6. Install the engine ECU using bolts (3). Connect connector EAEB (2). Install protective plate (1).
Figure 3
7. Close the radiator hood.
8. Turn on the electric power with the battery disconnect switch.
9. Start the engine and check that there are no faults.

Service Information

Injector, replacing 237 Service Information 2021-05-17
Profile:
L120E Volvo
Injector, replacing

Op nbr 23704
Figure 1
3. Raise engine covers (1)

Figure 2
Removing
4. Disconnect cables (1) from the preheating element. Unscrew four bolts (2) for the induction manifold at the preheating
element.
Figure 3
5. Remove cover (2) from the air cleaner and ejector hose (1) from the silencer. Remove hose (3) from the oil trap.
Figure 4
6. Remove the valve cover.

Figure 5
7. Remove fuel pipe (1) between the unit pump and the injector.
Figure 6
NOTE!
Replace the fuel pipe every time it has been removed.
NOTE!
Pay attention to the straightness.
8. Plug the connection by the pump unit.
9. Remove nozzle holder (2). Use Torx E10 (1).

Figure 7
10. Remove the injector by pulling it upwards:

NOTE!
The sealing washer installed at the lower end of the injector should always be replaced.
11. Clean the injector location in the cylinder head before installing the injector.
Installing
12. Fix copper washer (1) to the injector with a little grease.
Figure 8
13. Install the injector.

NOTE!
Install the injector with the drilled hole turned towards the valve springs.
Figure 9
14. Install retainer (2) and torque-tighten bolt (1). Use Torx E10. Tightening torque: 16 Nm ((12 lbf ft).
Figure 10
15. Remove the plug on the unit pump.
16. Install the fuel pipe and tighten the union nuts. Tightening torque: 40-50 Nm (30-37 lbf ft)
NOTE!
It is not permissible to bend the pipe.
Figure 11
17. Install the valve cover together with a new gasket and torque-tighten the bolts. Tightening torque: 9 Nm (6.6 lbf ft)
18. Install ejector hose (1) to the silencer and cover (2) on the air cleaner. Install hose (3) to the oil trap.
Figure 12
19. Install the preheating element using bolts (2) and connect electrical cables (1).
NOTE!
Always use a new gasket for the preheating element.
Figure 13
20. Turn on the current with the battery disconnect switch. Start the engine and check that there are no faults.
21. Close down the engine covers.
Figure 14
Service Information

Pump unit, replacing 237 Service Information 2021-05-17
Profile:
L120E Volvo
Pump unit, replacing


Op nbr 23676
2. Raise radiator hood (1) and open up hood panels (2).
Figure 1
Figure 2
4. Remove partition wall (1).
Figure 3
5. Carry out points 4-8 under "Injector, replacing"
6. Loosen overflow valve (1). Collect the fuel that runs out. Disconnect the hose from the fuel feed p ipe. If required,
carefully blow with compressed air into the fuel feed pipe to remove all fuel.
NOTICE
Avoid that remaining fuel runs into the oil sump and mixes with the oil when the pump unit is lifted away.
Removing
7. Disconnect the electrical leads from the pump unit.
Figure 4
8. Disconnect the fuel feed pipes from pump elements (1).
Figure 5
9. Slacken the attaching bolts approx. 4 mm (0.16 in) and loosen the unit pump from the block.
Figure 6
10. Crank the engine until the valves are rocking for the cylinder where the unit pump is to be replaced.
11. Unscrew the attaching bolts fully and remove the unit pump.
Figure 7
NOTE!
Spring force. Make sure that the unit pump does not jump up.
Installing
12. Check that O-rings (1) are undamaged.
Figure 8
13. Install the unit pump according to markings. Crank the engine so that the camshaft takes up a suitable position for the
respective unit pumps before tightening down the bolts.
Tightening torque step 1: 5 Nm (3.7 lbf ft).
Tightening torque step 2: 30 Nm (22 lbf ft).
14. Carry out points 16-21 under "Injector, replacing"
15. Reconnect the fuel feed pipe. The thicker copper washer should be placed between the feed pipe and the unit pump.
16. Bleed the fuel system according to the Operator's Manual
17. After installation, the operation "Unit pump, calibrating" (23691-2) should be carried out using VCADS Pro. Calibration
is only necessary for the unit pump or pumps that have been replaced.
Service Information

Unit pump, description 237 Service Information 2021-05-17
Profile:
L120E Volvo
Unit pump, description


The injector pumps are driven by the engine's camshaft. Each pump consists of two main parts: the pump part and the valve part
with solenoid valve.
Function
It's easiest to divide the events in the unit injector in four phases.
Filling phase
Filling takes place all the time that the piston moves down. The fuel valve is open since the solenoid valve is not supplied with
voltage. Therefore, fuel can be sucked from the feed channel through the open valve and into the pump cylinder.
Figure 1
Filling phase for unit pump
1. Solenoid valve
2. Fuel valve
3. Pump piston
4. Injector
Spill phase
The pump piston is on its way up. As long as the solenoid valve isn't supplied with voltage, the f uel valve remains open and fuel
flows in return to the feed channel.
Figure 2
Spill phase for unit pump
Injection phase
The pump piston is still on its way up. The solenoid valve is now supplied with voltage from the c ontrol unit and the valve closes.
Since fuel cannot flow through the valve, the pressure increases rapidly so that the injector needle lifts and injection takes place.
Injection continues for as long as the valve is closed and the pump piston moves up.
Injection timing depends on when in time the electric pulse arrives (when the fuel valve closes). The amount of fuel is determined
by the length (duration) of the electric pulse. It's the control unit that decides the pulse's duration and timing via information it
receives from the control system.
Figure 3
Injection phase for unit pump
Pressure reduction phase
The pump piston is still on its way up. The control unit terminates the electric pulse when the en gine has received the fuel
amount that it needs at exactly that point in time. The fuel valve opens and the fuel in the pump part can once again flow in
return to the feed channel.
Figure 4
Pressure reduction phase for unit pump
Summary
The pump piston always sucks the same amount of fuel as it pumps out of the injector. It's only when the fuel valve is closed that
pressure builds up and injection takes place.
The electric pulse's duration and its timing determines the injected fuel amount and when injection takes place.

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Service Information

Document Title: Function Group: Information Type: Date:

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Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

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Fuel feed pressure, checking

Valid for serial numbers

Pressure gauge 11 666 017

1. Park the machine in the service position.

2. Raise the left hood panel.

Document Title: Function Group: Information Type: Date:

Fuel feed pump, description

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

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Fuel feed pump, specifications

Valid for serial numbers

Fuel feed pump

Document Title: Function Group: Information Type: Date:

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Fuel system, bleeding

Valid for serial numbers

Total procedure time (hr): 0.40

 Open the bleeder screw (1) on the primary filter.

Document Title: Function Group: Information Type: Date:

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Fuel system, description

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Component list 11: sensors

Valid for serial numbers

Designation Wiring diagram Circuit no. Sensor type Function

SE301 8 3.270–3.280 Pressure Brake lights

SE406 12 4.190 Temperature Transmission oil temperature

SE502 15B 5.020 Pressure Low brake pressure

Designation Wiring diagram Circuit no. Sensor type Function

SE2502 28 2.260 Pressure monitor Air filter monitor

Document Title: Function Group: Information Type: Date:

Component list 12: switches

Valid for serial numbers

Designation Wiring diagram Circuit no. Function

SW100 1, 102 — Battery disconnect switch

SW301 6 3.010–3.130 Parking lights and headlights

SW305 8 3.260 Rotating warning beacon

SW403 9B 4.040 Activation Forward/Reverse, single lever⁽ᵃ⁾

Designation Wiring diagram Circuit no. Function

SW801A 18 8.010–8.025 Front wiper

SW805 19, 33 8.080 Cab fan

SW901 21, 21B, 21C 9.010 Bucket kickout

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Feeds E-ECU, I-ECU, V-ECU

Production location ARV ASH PED

Production location ARV ASH PED

Production location ARV ASH PED

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Document Title: Function Group: Information Type: Date:

Valid for serial numbers

Open the bleeder screw (1) on the primary filter.