Volvo L60F, L120F Service Manual

VOLVO CONSTRUCTION EQUIPMENT

Recycling Manual

L60F, L70F, L90F, L110F, L120F

MORE CARE. BUILT IN.

Foreword

Foreword

1

Foreword

Caring for the environment is one of Volvo’s core values, along with quality
and safety.

This brochure is for all those who work with dismantling and scrapping of a
complete machine, both service workshops as well as dismantling compa­nies and recycling companies. It can also be used for service work during
the machine’s lifetime, as a guide for handling used products that are
replaced during repairs and service.

The purpose is to facilitate correct handling of hazardous waste or other
equipment and components that may cause personal injury and environ­mental damage. It also serves as a material map to see which materials are
included in the product.

The brochure does not include any instructions for recycling technicians
since these will change with time, and an instruction from today may prove
to be completely different in the future. There is also national legislation and
a variety of local regulations that differ significantly.

The information in the brochure is developed for Volvo L60F, L70F, L90F,
L110F, and L120F, and shall not be used in any way for other products.

Information and data included in the brochure are valid at the time of publi­cation. We reserve the right to change specifications and equipment with­out prior notice.

This recycling manual is for a so-called ’basic machine’. When the machine
is purchased, a variety of optional equipment may be selected and all of
these are not included or described in this manual.

Overall perspective

Volvo Construction Equipment’s overall perspective on how environmental
aspects shall be fulfilled means that the company’s products are regarded
in a much greater context:

• Society works for common environmental legislation and facilitates good
work planning and provides systems for recycling.

• Volvo and its sub-suppliers replace materials that have negative impact
on man and the environment, and improve use of products and manufac­turing methods.

• Dealers make sure that the customers get the right machines that are ex­actly adapted to their applications.

• Operators and owners handle the machines correctly with regards to
use, service, and maintenance.

• Recycling is performed in a manner that is safe to both man and the en­vironment. Scrapping and dismantling take place in a way that enables
maximized reuse or recycling of the machine.

Safety

2

Safety

Safety

Volvo Construction Equipment AB assumes that work with our machines
follows the safety and work instructions included in the Service manual and
Operator’s manual for the model in question.

Dismantling and recycling of machines shall be performed by personnel
with sufficient knowledge, and in a professional manner in order to avoid
personal injury and environmental damage.

If in effect, national legislation governing dismantling of machines is the pri­mary legislation to be followed. This Recycling manual is only a supplement
to the valid Service manual and Operator’s manual for Volvo L60F, L70F,
L90F, L110F, and L120F.

Recycling work

Recycling work

3

Work and recycling

A Volvo wheel loader consists of metals to approx. 80%. In general, metals
are suitable for recycling. However, in certain cases the components’
design and installation may make recycling impossible, both practically and
economically, despite the included materials themselves being recyclable.

The recycling process has 5 readily identifiable steps, where one should
strive to get the biggest fractions of the machine’s material as high up as
possible on the recycling steps.

Recycling steps
Strive to get as much material as possible, as high as possible, on the steps.
Source: Thomas Magnusson IVF

Main work process when dismantling Volvo wheel loaders

This work process should be followed for dismantling work to proceed in
an optimal way:

1 Identify the machine by reading signs and plates as well as the instruc-

tions in the manual.

2 Check governing regulations/legislation for recycling and producer re-

sponsibility. Also check if there are special safety aspects for disman­tling.

3 Decontaminate the machine from fluids and specially marked compo-

nents that have to be removed and sorted out for special handling.

4 Dismantle the machine in a safe and environmentally correct manner.

5 Sort the dismantled parts and components in fractions for recycling.

Sorting

4

Sorting

Sorting

There is a number of thought fractions in which to sort the material, exam­ples of these are found below. Handling of these fractions is governed by
national legislation and local regulations, which shall be followed.

• Materials and components that can be reused as components in old
and/or new machines. These may be in need of repairs or upgrades in
order to meet quality requirements. For example, this may be engine, ax­les, transmission, and hydraulic cylinders.

• Materials that can be material-recycled with or without loss of quality. Ex­amples of material recycling without loss of quality are metals and certain
plastics. Loss of quality refers to, e.g., plastics that only can be given a
dark colour when material-recycled.

• Materials for energy extraction are, among others, unsorted plastics and
oils.

• Materials that have to be deposited mainly come from fragmentation and
unsorted materials.

Producer responsibility

A number of the machine’s components are governed by the principle of
producer responsibility, which means that they shall be taken care of
according to special instructions. These instructions may vary from one
country to another. If you do not know what this includes or are unsure
about applicable governing regulations, contact your Volvo dealer or Volvo
directly.

Identifying

Identifying

5

Identifying

Identifying the machines
This manual is only valid for the stated models; Volvo L60F, L70F, L90F,
L110F, and L120F, see illustration below for identification marking. The
machines have been manufactured in Sweden by Volvo Construction
Equipment AB from the year 2007. The primary colour is yellow.

Identifying

1 Machine PIN, Product Identification Number (stamped on right side).

2 Product plate including, among other things, machine type and PIN. Ad-

ditional plate with, among other things, CE-marking (only for country of
origin within the EU), as well as an emission plate. A total of three plates.

3 Plate identifying that ROPS-test has been performed and approved.

4 CIN-plate (Component Identification Number) for engine.

5 CIN-plate for transmission

6 CIN-plate for boom

7 CIN-plate for front axle

8 CIN-plate for rear axle

Materials - Identifying

6

Materials - Identifying

Marking – Standard

A marking system is used where all plastic parts are marked with a material
code, making the materials easy to identify. Many materials can be granu­lated and reused, while other plastics are used for energy extraction by
incineration. Certain plastics must be taken care of in a special way or
destroyed, through some form of pre-treatment.

Volvo standards applicable to these machines are:

• Std 103-0002 Material identification and marking of components made
of plastic or elastic material

• Std 5052,41 Material identification and marking of plastic parts

• Std 5052,411 Symbols and abbreviations

• Std 5052,412 Symbols for plastic containers

The following few examples show what the marking may look like:

>ABS< Part consisting of one material, in this case ABS-plastic.

>ABS+PC< Part consisting of a mix of two materials.

>PVC,PUR,ABS< Part consisting of 3 materials where PVD is the visible (coating) and PUR with inclusion of ABS. ABS is biggest by weight (under-

lined).

>PP – MD30< Part containing reinforcing or filler material with 30 percent by weight.

continuation

For more complicated mixtures, see Std 103-0002.

Contact your Volvo dealer or Volvo directly to obtain these standards.

Decontamination

Draining fluids 7

Decontamination

Draining fluids

Draining fluids

It is important that fluids are handled in a safe and correct manner, with
regards to national legislation as well as local regulations.
Follow instructions in the Service manual and Operator’s manual for drain­ing fluids in axles, tanks, and other containers and/or reservoirs.

The following table is intended to serve as a checklist.

Total volume in litres
Machine type

Position L60F L70F L90F L110F L120F

Engine, including filters 20 20 20 21 21

Transmission and torque converter, including filters 20 20 21 38 38

Front axle, including hub reduction 24 35 35 36 36

Rear axle, including hub reduction 24 27 27 41 41

Hydraulic system 135 135 135 215 215

Hydraulic oil tank 90 90 90 133 133

Fuel tank 219219219269 269

Cooling system 30 30 30 70 70

Oil bath pre-cleaner 5,5 5,5 5,5 9,1 9,1

Refrigerant (R134a) 2,1 kg 2,1 kg 2,1 kg 2,1 kg 2,1 kg

Washer fluid reservoir 5 5 5 5 5

Filter

Filter

There is a wide range of filters on the machine that, when dismantled, con­tain impurities and the medium which they filter. Note that there are special
regulations for handling of filters.

Filter table. This table is intended to serve as a checklist.

Number Position Medium Quanti-tyComments

1 Transmission Transmission oil 1

2EngineOil 3

3 Engine Coolant 1

4 Hydraulic tank Hydraulic fluid 1

5 Rear axle Oil 1 In comb. with axle oil cooling

6 Front axle Oil 1 In comb. with axle oil cooling

7 Air cleaner Air 2 Paper + filter

8Cab Air 2Paper filter

9Engine compart-

ment

- Breathing Air / oil mist 5 Axles, transmission, hydraulic tank, and fuel tank

Diesel 2

Decontamination

2

Components with special safety and environmental aspects8

5

8

1

6

Components with special safety and environmental aspects

Components with special safety and environmental aspects

The following components shall be handled with the extreme care and high­est safety. For handling, see Service manual and Operator’s manual.

9

Number Component Aspect

1 Battery Sulphuric acid

2 Accumulators for Boom Suspension System Pressurized container

3 Accumulators for lowering load Pressurized container

4 Accumulators for steering Pressurized container

5 Accumulators for service brake Pressurized container

6 Accumulators for P-brake Pressurized container

7 Air conditioning unit Refrigerant*

- Gaskets of fluor rubber/fluor silicone
(used to withstand high temperatures in, e.g., engines, transmissions, axles, hydraulic
motors, and pumps)

* Note that special regulations apply when working with refrigerant.
** Be extremely careful where you suspect presence of fluor rubber.
See Service manual and Operator’s manual for more information.

Generate hydrogen fluoride and hydrofluoric acid
when exposed to intense heat (fire). **)

Decontamination

1

Components with special safety and environmental aspects 9

2

3

4

5

6

7

Dismantling

Material weights, complete machine10

Dismantling

Material weights, complete machine

Material weights, complete machine

The following weights are approximate. They do not apply to machines with
optional equipment.
Volvo’s wheel loaders consist of metals to approx. 80%. In general, metals
are suitable for material recycling.

Material Weight in kg

Machine type

L60F L70F L90F L110F L120F

Steel/iron 9350 10830 12830 14830 15770

Copper 43 43 43 43 43

Aluminium 38 38 38 86 86

Bronze bushings 18 18 27 32 33

Lead batteries 60 60 60 81 81

Glass 74 74 74 74 74

Polymer materials & rubber 140 140 140 160 160

Tires 880 880 880 1290 1520

Fluids, oils, and chemicals 410 420 430 620 620

Other 440 620 1010 810 820

Total* 11450 13120 15080 18030 19210

* Varies depending on equipment, e.g., tires and bucket.

Components

8

3

11

Components

Number Component Weight in kg

L60F L70F L90F L110F L120F

1 Transmission 473 473 478 830 830

2 Counterweight 730 1397 2369 1880 2780

3 Engine 565 565 565 685 685

4 Boom 713 930 990 1220 1250

5 Front axle, complete 602 911 911 1080 1080

6 Rear axle, complete 608 688 688 1270 1270

7 Front frame 885 988 1150 1475 1475

8Rear frame 932963110211351135

9 Radiator for engine 72 72 72 737 737

10 Cab, complete 724 724 724 81 81

• Steel 503 503 503 516 516

• Plastics 81 81 81 81 81

• Glass 74747474 74

• Seat 36 36 36 36 36

10

9

7

4

2

1

6

5

Electronics

12

Electronics

Electronics

The machines have 4-6 so-called ECUs (Electronic Control Unit), and the
number of ECUs depends on what equipment is installed on the machine.
One is on the engine, one or two on the back wall in the cab, one in the
instrument panel, and one or two on the right side in the cab. In the cab
there are also two circuit boards, containing a number of relays and fuses.
One circuit board is located on the back wall and the other one is on the
right front pillar.

7

6

5

4

3

Position Part Material Note

1 V-ECU Circuit board + metal

1

2

2 Circuit board Circuit board

3 I-ECU Circuit board + plastic Instrument panel

4 ECC Circuit board + plastic Climate control unit (AC)

5 W-ECU Circuit board + plastic CareTrack

6 V2-ECU Circuit board + metal CDC + electric servo

7 Circuit board Circuit board Control panel

Plastics

Plastics

Plastics

Plastics 13

2

1

Number Part Material Note

1 Air ducts PP+elastic+mineral

2 Instrument panel PP+elastic+mineral

3

5

7

4

6

3Air duct ABS

4Cover PP

5Side panel PP

6 Air duct PP+elastic+mineral

7 Bottom part PP+elastic+mineral

Plastics

Plastics

Plastics14

3

2

1

Number Part Material Note

1Casing ABS

2Casing PC+ABS

3 Wrist support PUR

Plastics

Plastics

Plastics 15

3

2

Number Part Material Note

1 Floor mat PUR

2 Floor mat PUR

3 Exterior roof ABS + PMMA foil

1

Volvo Construction

Equipment

1032102

Plastics

Plastics

Plastics16

C

D

C

1

D

B

3

B

2

A

4

A

4

Number Part Material Note

1Exterior panel right PP+elastic+mineral

2 Cover right PP+elastic+mineral

3 Exterior panel left PP+elastic+mineral

4 Cover left PP+elastic+mineral 2 parts

Plastics

Plastics

Plastics 17

2

1

3

Number Part Material Note

1 Panel inside door ABS

2Panel inside rear ABS

3 Climate cover PP+elastic+mineral

4 Climate cover PP+elastic+mineral

4

Plastics

Plastics

Plastics18

1

2

3

Number Part Material Note

1 Ceiling (headlining) Polyester

2 Rearview mirror inside ABS 2 pcs.

3 Sun visor VELBEX Contains PVC

Plastics

Plastics

Plastics 19

1

Number Part Material Note

1Expansion tank PP

Plastics

Plastics

Plastics20

1

Number Part Material Note

1Fan shroudPDCPD

Plastics

Plastics

Plastics 21

1

2

2

Number Part Material Note

1 Washer fluid reservoir PP Motors (2) can easily be removed.

Plastics

Plastics

Plastics22

1

2

Number Part Material Note

1 Cover for air cleaner PP

2 Hose for air cleaner EPDM

Plastics

Plastics

Plastics 23

2

1

Number Part Material Note

1 Grill PDCPD Embedded steel bushings

2 Top part PDCPD

Plastics

Plastics

Plastics24

2

4

1

3

Number Part Material Note

1 Fender widener, front PP

2 Fender widener, rear PP

3 Splash guard, front Reinforced rubber cloth

4 Splash guard, rear Reinforced rubber cloth 2 pcs.

4

Plastics

Plastics

Plastics 25

1

Number Part Material Note

1Fuel tankHDPE

Plasticts

1

Plastics

Plasticts26

1

Number Part Material Note

1 Cover for battery box PP 2 pcs., one on each side

2 Battery Contains sulphuric acid, special handling required

2

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