Volvo BM L90C Wheel Loader Service Repair Manual Instant Download presentation

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Volvo BM L90C Wheel Loader Service Repair Manual Instant Download

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Volvo BM L90C Wheel Loader Service Repair Manual Instant Download –

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Title: Volvo BM L90C Wheel Loader Service Repair Manual Instant Download

1
Service Information
Document Title Description Function Group 400 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Description Loader L90C is provided with
transmission HT131. Loader L120C is provided with
transmission HT205. Both the HT131 and HT205 are
hydro-mechanical four-speed transmissions, with
torque converter, cylindrical spur gearings and
hydraulically controlled disc clutches. The
power from the engine to the wheels is
transmitted hydraulically and mechanically
through the transmission, via a torque converter
which adapts its output torque to the torque
requirements. The clutch drums for the different
gears turn freely on the clutch shafts. When a
gear is engaged, the clutch drum, which
transfers the force mechanically, is connected to
the respective clutch shaft by the disc clutches
which are applied hydraulically. The mechanical
transfer of power within the transmission takes
place via gear wheels which are in constant
mesh. L90C is provided with AWB30 drive axles.
L120C is provided with an AWB31 drive axle at the
front and an AWB30 drive axle at the rear. The
front axle can be equipped with a differential
lock.
2
Service Information
Document Title APS II (Automatic Power Shift with Mode Selector) Function Group 420 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
APS II (Automatic Power Shift with Mode
Selector) Description L90C and L120C are, as
standard, provided with APS II (Automatic Power
Shift with shift Mode Selector 1 ?, which is
included in the Contronic System control
unit. The following positions are
available LIGHT (first position) The machine
shifts at low engine speed, suitable for
transport operations without load. LIGHT
(second position) The machine shifts at a
slightly higher speed than the first position,
suitable for transport operations and lighter
loading / carrying work. NORMAL Is used for
"normal handling" and operation. HEAVY The
machine shifts at higher engine speeds, suitable
for heavier work. MAN Gear shifting is operated
manually by the operator using the gear selector.
Figure 1 Shift Mode Selector SW143 positioned on
the front panel Description of function during
manual gear shifting Mode Selector SW143 placed
in position "MAN" Gears are selected manually by
turning the gear selector to the required gear
position. Changing travelling direction After
changing travelling direction, the machine starts
off in the previously selected gear. NOTE!
3
As a safety precaution, upshifting to a higher
gear takes place if a certain critical travelling
speed and/or engine speed is exceeded. Descriptio
n of function during automatic gear shifting Mode
selector SW143 placed within the "AUTOMATIC"
range The gear selector placed in the 3rd or 4th
gear position. When starting from stationary this
takes place in 2nd gear and, if the machine is
rolling, it will start off in 3rd gear. The gear
shifting is automatic. Conditions required to
cause gear shifting is a combination of the
setting of the Mode Selector, travelling speed
and engine speed. Gear shifting between gears,
Forward 2nd - 3rd - 4th, Reverse 2nd - 3rd For
gear shifting down to 1st gear, see "Kick-down
function". Changing travelling direction Changing
travelling direction at low speed takes place in
2nd gear. If the speed is too high, 3rd gear will
first be engaged and then, when the speed has
dropped, 2nd gear will be engaged. Engine braking
/ downshifting 2nd gear is the basic gear and the
gear which the machine always starts off in when
operating with the selector set in 3rd or 4th
gear position. During engine retarding, the
accelerator control should be let up fully and
the engine braking / down-shift button SW105,
should be pressed in. Downshifting then takes
place in stages, with one gear for each time the
button is pressed, from 4th to 3rd and from 3rd
to 2nd, if the travelling speed is then below 22
km/h (13.7 mph). For a further downshifting to
1st gear, see "Kick-down function". If engine
braking / down-shift button, SW105, is kept
pressed in while the accelerator is actuated,
upshifting is prevented. Over-speeding
protection When downshifting, the control
programme always first checks that the travelling
speed is not too high for the selected gear. If
it is too high, the engaged gear will be retained
until the travelling speed has dropped to a
permissible level. Kick-down function Kick-down
means shifting down to 1st gear by activating the
kick-down function with SW90 on the selector
control, or SW105 on the control lever carrier.
The timing of the downshift to 1st gear depends
on the setting of the shift Mode Selector, the
engine speed and the travelling speed. 1st gear
will be engaged if the travelling speed of the
machine is sufficiently low or if the travelling
speed, within 8 seconds from that kick-down has
been activated, becomes sufficiently low. When
1st gear is engaged, this is indicated by a pip
from the buzzer. In order to shift up to 2nd
gear, the kick-down button must again be
actuated. NOTE! As a safety precaution,
upshifting to a higher gear takes place if a
certain critical travelling speed and/or engine
speed is exceeded. 1) APS II with Mode
Selector SW143 on the front panel is a
gear-shifting programme which is adjustable for
different operating and working conditions.
4
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5
Service Information
Document Title Gear selector valve Function Group 420 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Gear selector valve

Figure 1
Pressure connection from transmission pump
Connection to valve spool
Return to tank
When the solenoid is not activated, the valve
spool control side is connected to tank via the
solenoid (connection 2 - 3). The return spring,
which is positioned on the opposite side, presses
the valve spool toward the solenoid, see fig.
Invalid linktarget . When the solenoid is
activated, the solenoid core closes connection 3
to tank, the connection from the pump to the
valve spool is opened (connection 1 - 2), the
valve spool is pressed over to the opposite side,
see fig. 4.

6
Service Information
Document Title Operating with the ecu disconnected Function Group 420 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Operating with the ecu disconnected Op
nbr Nipple, part no. 957030, 2 pcs for operating
forward, 4 pcs for operating rearward Hose, part
no. 13932807, 1 pcs for operating forward, 2 pcs
for operating rearward
WARNING

when operating with the ecu disconnected, the
gear will be applied immediately the engine is
started, therefore keep the service brakes
applied when starting the engine.
Operating forward with the ecu disconnected
Remove the pressure checking point for the main
pressure, fig. Invalid linktarget for l90c and
fig. Invalid linktarget for l120c respectively
and plug n/d on the gear selector valve fig.
Invalid linktarget . Fit nipples part no.
957030.
Connect a hose part no. 13932807 between the
nipples.
Keep the selector control in neutral position and
start the engine.3rd gear forward will now be
applied.
When operating with the ecu disconnected is no
longer required, restore the check point and
plugs.

Figure 1
Gear selector valve
N/d valve spool, neutral - drive F/r valve
spool, forward - reverse
Operating rearward with the ecu disconnected
Remove the pressure checking points for the main
pressure and the 3rd clutch pressure on the
checking panel, fig. Invalid linktarget and
fig. Invalid linktarget for l90c and fig
Invalid linktarget for l120c respectively as
well as plugs n/d and f/r on the gear selector
valve fig. Invalid linktarget . Fit nipples
part no. 957030.
Connect a hose part no. 13932807 between the
outlet for the main pressure on the checking
panel and the outlet n/d on the gear selector
valve. Connect the other hose between the
pressure outlet for the 3rd clutch on the
checking panel and outlet f/r on the gear
selector valve.
Keep the selector control in neutral position and
start the engine.3rd gear reverse will now be
applied.
When operating with the ecu disconnected is no
longer required, restore the check points and the
plugs.

8
Service Information
Document Title Symbol diagram HT131 Function Group 420 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Symbol diagram HT131
Figure 1 Symbol diagram HT131
A Pressure-reducing valve, input torque converter pressure
PM Check point, main pressure
PC Check point, torque converter pressure
PL Check point, lubricating oil pressure
N/D Selector spool, neutral - drive
F/R Selector spool, forward - reverse
H/L Selector spool, high - low
1/2 Selector spool, 1st - 2nd
3/4 Selector spool, 3rd - 4th
R1 Damping valve, forward gear
R2 Damping valve, reverse gear
S1 Solenoid, neutral - drive
S2 Solenoid, forward - reverse
9
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10
S3 Solenoid, high - low gear
S4 Solenoid, 1st - 2nd gear
S5 Solenoid, 3rd - 4th gear
1 1st disc clutch
2 2nd disc clutch
3 3rd disc clutch
4 4th disc clutch
F Forward gear disc clutch
R Reverse gear disc clutch
The gear-shifting diagram shows the solenoids
which areactivated for the respective gears. For
instance, for 1F, solenoids S1, S3 and S4 are
activated.
11
Service Information
Document Title Symbol diagram HT205 Function Group 420 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Symbol diagram HT205
Figure 1 Symbol diagram HT205
PM Check point, main pressure
PC Check point, torque converter pressure
PL Check point, lubricating oil pressure
N/D Selector spool, neutral - drive
F/R Selector spool, forward - reverse
H/L Selector spool, high - low
1/2 Selector spool, 1st - 2nd
3/4 Selector spool, 3rd - 4th
R1 Damping valve, forward gear
R2 Damping valve, reverse gear
S1 Solenoid, neutral - drive
S2 Solenoid, forward - reverse gear
12
(No Transcript)
13
S3 Solenoid, high - low gear
S4 Solenoid, 1st - 2nd gear
S5 Solenoid, 3rd - 4th gear
1 1st disc clutch
2 2nd disc clutch
3 3rd disc clutch
4 4th disc clutch
F Forward gear disc clutch
R Reverse gear disc clutch
The gear-shifting diagram shows the solenoids
which areactivated for the respective gears. For
instance, for 1F, solenoids S1, S3 and S4 are
activated.
14
Service Information
Document Title Checking oil pressures, transmission Function Group 421 Information Type Service Information Date 2014/5/29
Profile Profile Profile Profile
Checking oil pressures, transmission Op nbr
42102 11 666 017 Pressure gauge, range 0 - 0.6
MPa (0 - 87 psi) 11 666 018 Pressure gauge, range
0 - 2.5 MPa (0 - 363 psi) 11 666 035 Hose 999
3721 Service display unit 930032 Measuring
nipple L90C Main pressure (neutral) 1.45 -
1.68 MPa (210 - 244 psi) Clutch pressure, 1st -
4th 1.35 - 1.58 MPa (196 - 229 psi) Clutch
pressure, Forward - Reverse 1.35 - 1.58 MPa (196
- 229 psi) Torque converter pressure, (out,
neutral) 0.57 - 0.69 MPa (83 - 100
psi) Lubricating oil pressure, (neutral) 0.35 -
0.45 MPa (51 - 65 psi) L120C Main pressure
(neutral) 1.37 - 1.58 MPa (199 - 229 psi) Clutch
pressure, 1st - 4th 1.37 - 1.58 MPa (199 - 229
psi) Clutch pressure, Forward - Reverse 1.37 -
1.58 MPa (199 - 229 psi) Torque converter
pressure, (out, neutral) 0.20 - 0.50 MPa (29 -
73 psi) Lubricating oil pressure, (neutral) 0.16
- 0.22 MPa (23 - 32 psi) The following applies
when checking Temperature Normal operating
temperature Speed High idling speed Use
measuring nipple 930032 where it is not already
mounted. NOTE! When checking the pressures, apply
service brakes and parking brake. Also make sure
that the transmission disengagement function is
not activated. NOTE! To be able to check the
clutch pressure for the 4th gear, without
activating the automatic shifting, the ECU must
be disconnected, see Fig. Invalid linktarget .
15

1.
Figure 1 Disconnecting ECU
Connector EY should be disconnected from the
circuit board
Connector EA should be disconnected from ECU and
connected on the circuit board, to connector EZ
Remove the lining from the rear cab wall so that
the electrical distribution box is accessible.
Disconnect the ECU by removing connector EY (blue
leads) from the circuit board.
Disconnect connector EA (yellow) from the control
unit and connect it to connector EZ (yellow) on
the circuit board.
L90C
Main pressure (alternative 1)
The main pressure can be read off with the aid of
the service display unit.
Connect service display unit 3721 to connector IA
on the steering wheel column.

8.
Figure 2
Gear selector valve
1. Pressure outlet main pressure
Connect pressure gauge 11 666 018 to the pressure
outlet on the gear selector valve, positioned
behind the cover door on the left side, see Fig.
Invalid linktarget
The gear selector should be in neutral position,
and the engine running at high idling speed.
Clutch pressure, 1st - 4th gear
Connect pressure gauge 11 666 018 to pressure
outlets items 1, 2, 3, or 4, see Fig. Invalid
linktarget
With the gear selector in the position for the
respective gears, check in both forward and
reverse gear at high idling speed.
Clutch pressure, forward and reverse gear

17
high idling speed. Lubricating oil pressure
14. Figure 3 Under the entry step on the left
side of the machine
R Pressure outlet reverse gear
F Pressure outlet forward gear
1 Pressure outlet 1st gear
2 Pressure outlet 2nd gear
3 Pressure outlet 3rd gear (provided with quick-action coupling)
4 Pressure outlet 4th gear
5 Pressure outlet, lubricating oil pressure (provided with quick-action coupling)
Connect pressure gauge 11 666 017 to pressure
outlet item 5 Fig. Invalid linktarget . High
idling speed. Torque converter pressure
18

15.
Figure 4
1 Pressure outlet, torque converter valve
Connect pressure gauge 11 666 017 to the pressure
outlet on the torque converter delivery valve,
positioned behind the cover door on the right
side, see Fig. Invalid linktarget .
The gear selector in neutral position, high
idling speed.
After the pressure checks have been completed,
reconnect the connectors in the electrical
distribution box and re- fit the wall lining.
Clutch pressure diagram

Lubricati ng oil Torque converte r Main pressure Clutch pressure Clutch pressure Clutch pressure Clutch pressure Clutch pressure Clutch pressure
F B 1 2 3 4
N X X X 0 0 0 0 X 0
1F X X X X 0 X 0 0 0
2F X X X X 0 0 X 0 0
19
3F X X X X 0 0 0 X 0
4F X X X X 0 0 0 0 X
1R X X X 0 X X 0 0 0
2R X X X 0 X 0 X 0 0
3R X X X 0 X 0 0 X 0
4R X X X 0 X 0 0 0 X
X Pressure X Pressure X Pressure X Pressure X Pressure X Pressure X Pressure X Pressure X Pressure X Pressure
0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure 0 Without pressure
Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above. Any operating problems caused by internal leakage in the gear selector valve or between clutch shaft and oil distributor, can be determined if all the different pressures for the transmission are checked at the same time as described above.

L120C
Main pressure (alternative 1)
The main pressure can be read off with the aid of
the service display unit.
Connect service display unit 3721 to connector IA
on the steering wheel column.
The gear selector should be in neutral position
and the engine running at high idling speed.
Main pressure (alternative 2)

22. Figure 5 Under the entry step on the right
side of the machine
1 Pressure outlet 1st gear
2 Pressure outlet 2nd gear
3 Pressure outlet 3rd gear (provided with quick-action coupling)
4 Pressure outlet 4th gear
R Pressure outlet reverse gear
F Pressure outlet forward gear
H Pressure outlet main pressure (provided with quick- action coupling)
Connect pressure gauge 11 666 018 to the pressure
outlet item 7, see Fig. Invalid linktarget
. 23. The gear selector should be in neutral
position and the engine running at high idling
speed. Clutch pressure, 1st - 4th gear
20

Connect pressure gauge 11 666 018 to the pressure
outlets items 1, 2, 3 or 4 (certain markets only
3) see Fig. Invalid linktarget .
The gear selector should be in the position for
the respective gears. Check in both forward and
reverse position with the engine running at high
idling speed.
Clutch pressure, forward and reverse gear
Connect pressure gauge 11 666 018 to items F or
R, see Fig. Invalid linktarget .
The gear selector should be in forward or reverse
position respectively with 3rd gear engaged and
the engine running at high idling speed.
Torque converter pressure and lubricating oil
pressure

28.
Figure 6
Lubricating oil pressure
Torque converter pressure
Connect pressure gauge 11 666 017 on the left
side of the transmission, item 1 lubricating oil
pressure, or item 2 torque converter pressure,
see Fig. Invalid linktarget .
The gear selector should be in neutral position
and the engine running at high idling speed.
NOTE!
The torque converter pressure depends on
temperature, speed and the resistance in the
system which varies, but is limited at its
lowest by the lubricating oil pressure and at its
highest by the safety valve which opens at 0.8
MPa (116 psi).
After the pressure checks have been completed,
reconnect the connectors to the electrical
distribution box and re- fit the wall lining.
Clutch pressure diagram

2.
Figure 1
1. E1370
Axle stands
Position support (e 1370) under the lifting
frame, see fig. Invalid linktarget .
Remove protective cover (17) over microswitch
(18) for the differential lock, see fig. Invalid
linktarget .
Remove cover (13), thrust washer (22) and
diaphragm (15) above the differential lock
diaphragm sleeve (7). Remove push rod (5) lock
screw (8) with the aid of a 5 mm allen key.
Screw the diaphragm sleeve counter-clockwise
until the differential lock is fully engaged, but
without any pre- tension. Check by rotating one
of the wheels of the machine forwards and
backwards.
Then screw the diaphragm sleeve clockwise 4
revolutions so that the differential lock is
disengaged and then lock pushrod (5) with lock
screw (8). Fit diaphragm (15).
Fix thrust washer (22) with petroleum jelly in
cover (13). Then re-fit the cover. Check that the
differential lock is disengaged by rotating a
wheel.

23
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Figure 2
Locking clamp
Stud
Bolt
Cotter pin
Pushrod
Lock nut
Diaphragm sleeve (thrust sleeve)
Lock screw
Return spring
Filter
Piston
O-ring
Cover
Pressure connection
Diaphragm
Support washe
Protective casing

25
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friend! Thank you very much for reading. Enter
the link into your browser. The full manual is
available for immediate download. https//www.eb
ooklibonline.com

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