Asphalt Compactors Volvo PT220, PT220 RH Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Volvo Construction Asphalt Compactors PT220, PT220 RH, with all the workshop information to maintain, diagnose, repair, and service like professional mechanics.
Asphalt Compactors PT220, PT220 RH Volvo workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS
Asphalt Compactors Volvo PT220 Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 956
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
000 - GENERAL.....2
00 - DESCRIPTION; COMPLETE MACHINE.....3
Description, complete machine.....4
Engine, identification.....6
Location of components.....7
Machine identification.....9
Operator's protective structure, component locations.....11
Plates and reflectors.....12
Stopping.....14
03 - SPECIFICATIONS.....15
Alternator, specifications.....16
Back-up alarm, specifications.....17
Battery, specifications.....18
Brakes, specifications.....19
Critical mounting torques.....20
Diesel fuels - quality and function.....21
Dual function alarm, specification.....22
Electric horn, specifications.....23
Engine, specifications.....24
Frame, specifications.....25
Fuel, lubricant and filling capacities.....26
Glossary of Abbreviations.....27
Hydraulic connections, tightening torques.....28
Machine dimensions.....30
Machine weights.....33
Measurement conversion tables.....34
Power transmission, specifications.....38
Specifications, general.....40
Starter motor, specifications.....41
Steering system, specifications.....42
Tightening torque, specifications.....43
Tyre sizes and pressures specifications.....45
05 - TRANSPORT, STORAGE, OPERATING INSTRUCTION.....46
Transporting the machine.....47
07 - STANDARD TIME.....49
Operation numbers for additional work.....50
001 - STANDARD PARTS, SERVICE.....52
16 - LUBRICANT; FUEL; OTHER FLUID.....53
Alternative fuels.....54
Coolant mixture.....57
Environmentally safe handling.....58
Hydraulic oil, specifications.....59
Lubricant recommendation.....60
Lubrication and service chart.....61
Lubrication and service schedules.....62
Recommended lubricants.....63
17 - SERVICE.....65
Air cleaner primary filter, cleaning.....67
Air cleaner system, checking.....71
Air cleaner, primary filter replacing.....72
Air cleaner, secondary filter replacing.....75
Arrival Inspection, according to Inspection Programme.....78
Battery disconnect switch (main switch), check.....79
Battery, checking electrolyte.....81
Battery, maintenance.....83
Cleaning engine compartment.....85
Cleaning prior to repair.....87
Coolant level, check.....89
Coolant, changing.....90
Cooling fan, check.....93
Delivery Inspection, according to Inspection Programme.....94
Electric welding.....95
Electrical components, basic check.....96
Engine oil filter, replacing.....97
Engine oil level, check.....99
Engine oil, changing.....101
Fuel filters, replacing.....104
Fuel level, checking.....106
Fuel system, bleeding.....108
Fuel water separator, drain.....110
Greasing.....111
Hydraulic oil suction strainer, cleaning.....114
Hydraulic oil suction strainer, replacing.....117
Hydraulic oil, changing.....120
Hydraulic system, checking oil level.....123
Lap type seat belt, checking and maintenance.....124
Maintenance of Stored Machines, according to Inspection Programme.....125
Maintenance service, as required.....126
Maintenance service, daily.....127
Maintenance service, every 1000 hours.....128
Maintenance service, every 2000 hours.....129
Maintenance service, every 250 hours.....130
Maintenance service, every 50 hours.....131
Maintenance service, every 500 hours.....132
Maintenance service, every 6000 hours.....133
Maintenance service, general.....134
Parking brake performance.....136
Precaution when working on the electrical system.....138
Radiator and coolers, cleaning.....139
Starting with booster batteries.....141
Steering cylinder pins, greasing.....143
Towing a disabled machine.....144
Tyres, wear and air pressure, checking.....148
Water filter, changing.....149
Water separator filter, replacing.....150
Water tank and spray bars, drain and flush.....152
Water tank level, checking_{04-37-41}.....155
Water tank level, checking_{04-37-51}.....157
Wheel nuts, check torque.....159
or alternator belt, checking and adjusting tension.....160
19 - GENERAL.....163
Check list after fire or heat exposure.....164
Fire prevention measures.....165
Handling hazardous materials.....168
Health hazards with paint, plastics and rubber.....170
Safety concerns everybody!.....172
Safety when handling oil and fuel.....173
Safety when handling the machine.....174
Safety when lifting and supporting complete machine.....176
Safety when servicing.....178
Safety when working on hydraulic systems.....181
Safety when working with batteries.....182
Service position 1.....184
Some simple rules regarding tyre handling.....187
Waste handling.....189
002 - ENGINE WITH MOUNTING AND EQUIPMENT.....190
20 - GENERAL.....191
Engine components.....192
Engine difficult to start.....194
Engine trouble shooting.....195
Engine, description.....202
Heavy exhaust smoke development.....203
21 - ENGINE.....204
Engine mounts, replacing.....205
Engine, installing.....207
Engine, removing.....216
Valves, adjusting.....224
23 - FUEL SYSTEM.....230
Fuel lines, replacing_{04-15-57}.....231
Fuel lines, replacing_{04-16-08}.....234
Fuel lines, replacing_{04-16-21}.....236
Fuel lines, replacing_{04-16-32}.....239
Fuel system, description.....241
Fuel tank breather cap, replacing.....243
Fuel tank lid cover plate gasket, replacing.....246
Fuel tank sight gauge, replacing.....248
Fuel tank, description.....249
Fuel tank, installing.....250
Fuel tank, removing.....254
25 - INLET & EXHAUST SYSTEM.....258
Air cleaner, installing.....259
Air cleaner, removing.....261
Air duct rubber ring, replacing.....263
Air duct, replacing.....265
Air filter clog sensor, replacing.....267
Air hose, air duct, elbow, replacing.....269
Charge air cooler inlet pipe, replacing.....270
Charge air cooler outlet pipe, replacing.....273
Charge air cooler, removing.....275
Exhaust system, description.....277
Flexible pipe, replacing_{04-14-27}.....278
Flexible pipe, replacing_{04-14-39}.....282
Inlet system, description.....286
Pre-cleaner, replacing.....288
Silencer, replacing.....290
26 - COOLING SYSTEM.....295
Cooling fan, replacing.....296
Cooling package, installing.....297
Cooling package, removing.....301
Cooling system, description.....305
Expansion tank, replacing.....306
Fan guard, replacing.....309
Radiator hose upper, replacing.....312
Radiator hoses lower, replacing.....315
Radiator, replacing.....318
or alternator belt, replacing.....321
27 - ENGINE CONTROL.....325
Throttle control assembly, replacing.....326
Throttle control cable, replacing.....330
Throttle control lever, replacing.....335
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....339
30 - GENERAL.....340
Electrical system, description.....341
Electrical system, specifications.....342
Electrical troubleshooting.....343
Solenoid valve, check.....358
Special instructions for working on the electrical system.....359
Switch, check.....360
31 - BATTERY.....364
Battery description.....365
Battery storage.....366
Battery, charging.....367
Battery, check.....369
Battery, connecting.....371
Battery, disconnecting.....372
Battery, installing_{04-04-30}.....373
Battery, removing_{04-04-21}.....375
Explosion hazard.....377
32 - ALTERNATOR; CHARGE REGULATOR.....378
Alternator, description.....379
Alternator, installing.....380
Alternator, removing.....382
Alternator, testing.....384
33 - STARTING SYSTEM.....386
Starter motor, description.....387
Starter motor, replacing.....388
35 - LIGHTING.....390
Component location, lights.....391
General.....393
Headlamp, replacing.....394
Licence plate lamp, replacing.....396
Lights, specifications.....397
Tail lamp, replacing.....398
Work lamp, replacing_{03-57-55}.....400
Work lamp, replacing_{03-58-05}.....402
36 - OTHER ELECTRICAL EQUIPMENT.....404
Back up alarm, replacing.....405
Back-up alarm, description.....407
Component list, Switches.....408
Component location, switches_{03-31-01}.....410
Component location, switches_{03-31-14}.....411
Control box limit switch, checking.....412
Control box limit switch, replacing.....414
Diode, replacing_{03-29-57}.....416
Diode, replacing_{03-30-09}.....418
Dual function alarm, description.....419
Dual function alarm, replacing.....420
Emergency stop switch, replacing.....423
Horn, description.....426
Horn, replacing.....427
Ignition switch, replacing_{03-32-02}.....428
Ignition switch, replacing_{03-32-15}.....430
Ignition switch.....432
Indicator lamp High beam , replacing.....434
Indicator lights.....436
Reverse alarm switch, replacing.....438
Switch, replacing_{03-15-58}.....440
Switch, replacing_{03-35-58}.....442
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....444
Battery cable +, replacing_{03-21-30}.....446
Battery cable negative, replacing.....448
Battery disconnect switch.....451
Battery disconnector, replacing.....452
Colour codes.....454
Component list, Solenoid valves.....455
Component list, fuses.....456
Component list, relays.....457
Component location, fuses.....458
Component location, relays.....460
Electrical distribution box, circuit board replacing.....462
Electrical symbols and designations.....465
Engine oil pressure sensor, replacing.....467
Engine wire harness, replacing.....469
Flasher relay, replacing.....473
Front wire harness, replacing.....475
Fuse (general), replacing.....478
Fuse box, changing.....479
Hour meter, replacing.....481
Instrument panel, description_{03-16-35}.....483
Instrument panel, description_{03-16-49}.....486
Instrument panel, description_{03-17-06}.....489
Instrument panel, description_{03-17-20}.....492
Instrument panel, description_{03-17-37}.....495
Instrument panel, description_{03-17-50}.....498
Instrument wire harness, replacing.....501
Light relay, replacing.....510
Motometer, replacing.....512
Platform wire harness, replacing.....514
Power relay, replacing.....518
Rear wire harness, replacing.....520
Relay (general), replacing.....526
Resistor, replacing.....528
Temperature sensor cooling system, replacing.....530
Water flow control, replacing_{03-16-03}.....532
Water flow control, replacing_{03-16-18}.....535
Wiring diagram_{03-24-26}.....537
Wiring diagram_{03-24-48}.....540
Wiring diagram_{03-25-09}.....545
Wiring diagrams, component list and index_{03-25-24}.....550
Wiring diagrams, component list and index_{03-25-36}.....552
004 - POWER TRANSMISSION.....554
40 - GENERAL.....555
Power Transmission, Propulsion.....556
42 - TRANSMISSION; HYDRAULIC CONTROL.....565
Neutral safety switch, checking.....566
Neutral safety switch, replacing_{03-11-40}.....568
Neutral safety switch, replacing_{03-11-54}.....571
Propulsion control cable, replacing.....574
Propulsion control lever clamp attachment, replacing_{03-10-54}.....579
Propulsion control lever clamp attachment, replacing_{03-11-07}.....582
Propulsion control lever, replacing.....585
Propulsion rod, pipe, installing.....590
Propulsion rod, pipe, removing.....596
44 - HYDROSTATIC DRIVE.....602
Hydraulic motor, installing.....603
Hydraulic motor, removing.....608
Propulsion pump coupling, installing.....612
Propulsion pump coupling, removing.....614
Propulsion pump manifold, replacing.....617
Propulsion pump, installing_{03-07-04}.....620
Propulsion pump, removing_{03-06-50}.....625
005 - BRAKE.....629
Brake, description.....630
Parking brake pressure switch, replacing.....631
Parking brake, function description.....633
006 - STEERING.....636
60 - GENERAL.....637
Steering system, description.....638
64 - STEERING.....640
Control console wheel, replacing.....642
Control panel lock pin spring, replacing.....644
Control panel lock pin, replacing.....646
Control panel lock plate, replacing.....650
Control panel rail, guide, replacing.....651
Control panel stop plate, replacing.....656
Control panel, replacing.....658
Flexible hose, replacing.....668
Pivot bushing, replacing.....677
Pivot, installing_{02-59-39}.....679
Pivot, removing_{02-59-20}.....682
Steering arm, installing_{03-00-16}.....685
Steering arm, installing_{03-00-49}.....688
Steering arm, removing_{03-00-01}.....691
Steering arm, removing_{03-00-35}.....695
Steering column, installing.....699
Steering column, removing.....702
Steering control unit, description and operation.....705
Steering cylinder bearings, replacing.....707
Steering cylinder, description.....708
Steering cylinder, installing.....709
Steering cylinder, removing.....711
Steering hydraulic schematics.....713
Steering pump, installing.....715
Steering pump, removing.....718
Steering valve, installing_{02-55-42}.....720
Steering valve, removing_{02-55-28}.....722
Steering wheel, description.....724
Steering wheel, replacing.....726
Track rods, installing_{02-58-46}.....729
Track rods, removing_{02-58-34}.....731
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....733
71 - FRAME.....734
Cap support, replacing.....735
Cover plates gasket, replacing.....737
Frame, description.....741
72 - SUSPENSION.....743
Suspension cylinder adjustment.....744
Suspension cylinder connecting tube, replacing.....748
Suspension cylinder, description.....750
Suspension cylinder, installing_{02-51-54}.....752
Suspension cylinder, installing_{02-52-32}.....756
Suspension cylinder, removing_{02-51-39}.....760
Suspension cylinder, removing_{02-52-15}.....765
Suspension cylinder, specification.....770
75 - AXLE SUSPENSION.....771
Drive shaft, installing_{02-50-00}.....772
Drive shaft, installing_{02-50-30}.....777
Drive shaft, installing_{02-50-59}.....782
Drive shaft, removing_{02-49-46}.....787
Drive shaft, removing_{02-50-15}.....791
Drive shaft, removing_{02-50-44}.....795
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....799
Front wheel, installing.....800
Front wheel, removing.....803
Rear wheel, installing.....807
Rear wheel, removing.....810
Wheels, general description.....814
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....816
81 - CAB, NAKED; CANOPY.....817
Operator's protective structure, description.....818
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....820
Engine hood hinge, replacing.....821
Engine hood latch, replacing.....824
Engine hood sealing, replacing.....826
Engine hood, changing gas spring.....827
Engine hood, installing.....829
Engine hood, opening and closing.....831
Engine hood, removing.....833
Foot step.....835
Hand rail, installing.....837
Hand rail, removing.....839
License plate.....842
83 - DOORS; HATCH; COVER PLATE, (all).....844
Deck plates, replacing.....845
85 - CAB INTERIOR; UPHOLSTERY.....848
Operator's seat, installing.....849
Operator's seat, removing.....850
86 - PROTECTIVE EQUIPMENT.....852
ROPS (Roll Over Protection), installing.....853
ROPS (Roll Over Protection), removing.....855
89 - MISCELLANEOUS.....857
Compressed air system.....858
Tyre inflation components, replacing.....860
Unloading valve,replacing.....862
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....864
90 - GENERAL.....865
Hydraulic oil, description.....866
Hydraulic oil, storing and handling.....867
Hydraulic system troubleshooting.....868
Hydraulic system, description.....874
Hydraulic tank, volume.....875
Oil and filtration.....876
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....877
Check valve, replacing_{02-32-23}.....878
Check valve, replacing_{02-32-37}.....881
Combination valve, replacing.....883
Explanations to hydraulic diagram.....886
Hydraulic couplings, description.....889
Hydraulic couplings, installation instructions.....890
Hydraulic diagram, schematic.....892
Hydraulic manifold block LH, replacing.....895
Hydraulic manifold block RH, replacing.....898
Hydraulic oil cooler, description.....900
Hydraulic oil cooler, replacing.....901
Hydraulic oil level gauge, replacing.....903
Hydraulic tank breather cap, replacing.....905
Hydraulic tank lid cover plate gasket, replacing.....908
Hydraulic tank, description.....910
Solenoid coil, replacing.....912
Solenoid valve, replacing.....914
Valve block, installing.....916
Valve block, removing.....919
98 - FUNCTION FOR ROAD CONSTRUCTION.....921
Ball valve, replacing.....922
Cocoa mats, replacing.....927
Water pump, installing.....929
Water pump, removing.....933
Water spray system components, replacing_{02-28-58}.....936
Water spray system components, replacing_{02-29-10}.....940
Water spray system, description.....941
Water strainer, replacing.....944
Water tank, installing.....949
Water tank, removing.....953
Asphalt Compactors Volvo PT220, PT220 RH Service Repair Manual
