Volvo L20H Compact Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L20H Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo Construction L20H Compact Wheel Loader 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.
PRODUCT DETAILS:
Total Pages: 987 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Volvo L20H Compact Wheel Loaders Service Repair Manual.pdf
MAIN SECTIONS
000 - Foreword.....2
000 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Description.....5
03 - SPECIFICATIONS.....7
Measurement conversion tables.....8
Volvo standard tightening torques.....13
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.....15
Transporting the machine.....16
07 - STANDARD TIME.....18
Operation numbers for additional work.....19
08 - TOOL.....21
E-tool Cab support.....22
E-tool Guide bolts.....23
E-tool Sleeve.....24
Infrared Thermometer.....25
001 - STANDARD PARTS, SERVICE.....29
16 - LUBRICANT; FUEL; OTHER FLUID.....30
Alternative fuels.....31
Coolant with freezing and corrosion protection.....34
Fuel, recommendation.....35
Lubricants and filling capacities.....36
Recommended lubricants.....38
17 - SERVICE.....40
Arrival Inspection, according to Inspection Programme.....42
Axle oil, changing.....43
Battery, checking.....46
Brake fluid level, checking.....47
Cab main filter, replacing.....48
Charging batteries.....50
Cleanliness, braking and hydraulic system.....51
Coolant freezing point, checking.....52
Coolant level, checking.....54
Coolant, changing.....56
Crankcase ventilation separator element, replacing.....59
Delivery Inspection, according to Inspection Programme.....61
Delivery Instructions, according to Inspection Programme.....62
EGR system, checking.....63
Electric welding.....72
Engine air cleaner primary filter, replacing.....73
Engine air cleaner secondary filter, replacing.....75
Engine belt tension, checking.....76
Engine oil and filter, changing.....78
Engine oil level, checking.....80
Fuel filters, replacing.....81
Fuel injectors, checking.....83
Fuel tank breather filter, replacing.....84
Hydraulic oil filters, replacing.....85
Hydraulic oil level, checking.....87
Hydraulic oil, changing.....88
Hydraulic pressure, checking.....90
Hydraulic tank sediment, draining.....96
Leakage, checking.....97
Lubrication.....98
MATRIS and Tech Tool, reading.....100
Maintenance of Stored Machines, according to Inspection Programme.....101
Maintenance service, every 10 hours.....102
Maintenance service, every 100 hours.....103
Maintenance service, every 1000 hours.....104
Maintenance service, every 1500 hours.....106
Maintenance service, every 2000 hours.....108
Maintenance service, every 3000 hours.....110
Maintenance service, every 500 hours.....112
Maintenance service, every 6000 hours.....113
Radiator, cleaning.....114
Service and maintenance.....116
Service brake pads, checking.....118
Service position 1.....119
Service position 2.....121
Service.....123
Steering cylinders, locking of pivot pins, checking.....124
Steering pressure, checking .....125
Tech Tool, operations.....127
Test running and checking.....128
Towing a disabled machine.....129
Turbocharger, checking.....131
Tyre wear and air pressure, checking.....132
Valves, adjusting.....133
Water separator, checking.....138
Wheel nuts torque, checking.....139
Work on the machine's electrical system.....140
19 - GENERAL.....141
CE-marking, EMC-directive.....142
Checklist after a fire or heat exposure.....146
Decontamination.....147
Environmental handling for the future.....149
Environmentally hazardous fluids.....151
Environmentally safe handling.....152
Fire prevention measures.....154
Health hazards with paint, plastics and rubber.....157
Loader boom, safety strut.....159
Safety concerns everybody!.....162
Safety rules when servicing.....164
Safety when handling accumulators.....167
Safety when handling oils and fuel.....168
Safety when handling the machine.....169
Safety when lifting and supporting complete machine.....173
Safety when using lifting equipment.....175
Safety when working on hydraulic systems.....177
Safety when working with batteries.....179
Safety when working with refrigerant.....182
Service position 1_{01-33-23}.....185
Service position 2_{01-33-51}.....187
Some simple rules regarding tyre handling.....189
Starting with booster batteries.....191
Waste handling.....193
Working in environmentally contaminated areas.....194
Working under raised boom.....195
002 - ENGINE WITH MOUNTING AND EQUIPMENT.....196
20 - GENERAL.....197
E-ECU MID 128 non-programmed, replacing.....198
E-ECU MID 128 pre-programmed, replacing.....200
Engine electric components, component locations.....202
Engine refill capacities, specifications.....204
Engine weight, specifications.....205
Engine, component locations.....206
Engine, description.....209
Tech Tool, operations .....212
21 - ENGINE.....213
Cylinder compression, testing.....214
Engine, installing.....216
Engine, removing.....225
Engine, specifications.....235
Valve cover, installing.....236
Valve cover, removing.....239
Valves, adjusting.....242
22 - LUBRICATING SYSTEM.....246
Lubricating system, description.....247
Lubrication oil pressure, checking.....251
Lubrication system, specifications.....253
Lubrication system, tightening torques.....254
Oil cooler, replacing.....255
Oil pressure relief valve, replacing.....257
23 - FUEL SYSTEM.....260
Fuel cooler, replacing.....261
Fuel pump unit, replacing.....263
Fuel system, description.....271
Fuel system, specifications.....276
Fuel system, tightening torques.....277
Fuel tank level sensor, replacing.....278
Fuel tank, capacities.....281
Fuel tank, replacing.....282
Injectors, replacing.....293
25 - INLET & EXHAUST SYSTEM.....296
Charge air cooler, replacing.....297
Exhaust Aftertreatment System, description.....299
Inlet and exhaust system, component location.....302
Inlet and exhaust system, description.....304
26 - COOLING SYSTEM.....308
Coolant pump, replacing.....309
Cooling fan clutch, replacing.....313
Cooling package, installing.....316
Cooling package, removing.....320
Cooling system, capacity.....326
Cooling system, description.....327
Fan belt and_or alternator belt, replacing.....330
Thermostat, replacing.....333
29 - MISCELLANEOUS.....335
Exhaust Gas Recirculation (EGR), description.....336
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....340
30 - GENERAL.....341
AL3201, description and measuring.....343
Automatic engine shut down, description.....345
Collection of basic data.....347
Component descriptions.....349
Conditions when checking.....352
Electrical system, description.....355
Electrical system, special instructions for servicing, electrical components, batteries.....357
Electrical system, special instructions for servicing, electronic components.....359
Electrical system, special instructions for servicing, general.....360
Electrical system, specifications.....362
FX1005, description and measuring.....363
FX1052, description and measuring.....366
FX1053, description and measuring.....369
General fault diagnosis information.....371
HE2501, description and measuring.....373
Lead and connector checks.....375
Limp Home.....379
MA2301-MA2304, description and measuring.....381
MA2310, description and measuring.....383
MA4220, description and measuring.....385
MA4221, description and measuring.....387
MA4605, description and measuring.....389
MA4710_MA4711, description and measuring.....391
MA4720, description and measuring.....394
RE01, description and measuring.....397
RE04, description and measuring.....399
RE05, description and measuring.....401
RE2501, description and measuring.....403
RE3301, description and measuring.....405
RE3501, description and measuring.....407
RE3502, description and measuring.....409
RE8701, description and measuring.....411
SAE J1939_CAN1 Control link, description and measuring.....413
SAE J1939_CAN2 control link, description and measuring.....415
SAE error codes, translation to error messages, general.....417
SE2206, description and measuring.....419
SE2303, description and measuring.....421
SE2306, description and measuring.....423
SE2309, description and measuring.....425
SE2502, description and measuring.....427
SE2507, description and measuring.....429
SE2508, description and measuring.....431
SE2606, description and measuring.....434
SE2702, description and measuring.....436
SE2709, description and measuring.....438
SE2710, description and measuring.....441
SE4307, description and measuring.....444
SE9105, description and measuring.....446
SE9106, description and measuring.....448
SW4205_SW4206, description and measuring.....450
Software parameters, description.....452
Special tools for troubleshooting.....456
Tech Tool, operations.....457
Troubleshooting strategy.....458
32 - ALTERNATOR; CHARGE REGULATOR.....460
Alternator, replacing incl function checking.....461
Alternator, testing.....463
33 - STARTING SYSTEM.....465
Glow plug, installing.....466
Glow plug, removing.....468
Glow plugs, testing.....470
Preheating, specifications.....471
Starter motor, replacing.....472
Starter relay, replacing.....474
36 - OTHER ELECTRICAL EQUIPMENT.....475
Windscreen wiper front motor, replacing.....476
37 - CABLE; FUSE; RELAY.....482
Cable and component designations.....484
Cable and component marking explanations.....486
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.....488
Component list Fuses.....490
Component list Heating coils, instruments, service socket.....493
Component list Lights.....494
Component list Relays.....496
Component list Solenoid valves.....498
Component list Switches.....499
Component list, PWM valves.....501
Component list, Sounders.....502
Component list, motors.....503
Component list, sensors.....504
Component location 1.....505
Component location 10.....507
Component location 11.....509
Component location 2.....511
Component location 3.....512
Component location 4.....513
Component location 5.....514
Component location 6.....517
Component location 7.....519
Component location 8.....521
Component location 9.....523
Component location.....526
Connector I_O description.....527
Electrical symbols and designations.....545
Table of contents, wiring diagrams.....549
Wiring diagram WD201.....550
Wiring diagram WD202.....553
Wiring diagram WD203.....556
Wiring diagram WD301.....559
Wiring diagram WD302.....562
Wiring diagram WD303.....565
Wiring diagram WD304.....568
Wiring diagram WD305.....571
Wiring diagram WD306.....574
Wiring diagram WD307.....577
Wiring diagram WD308.....580
Wiring diagram WD309.....583
Wiring diagram WD310.....586
Wiring diagram WD311.....589
Wiring diagram WD312.....592
Wiring diagram WD313.....595
Wiring diagram WD314.....598
Wiring diagram WD315.....601
Wiring diagram WD401.....604
Wiring diagram WD501.....607
Wiring diagram WD801.....610
Wiring diagram WD802.....613
Wiring diagram WD803.....617
Wiring diagram WD901.....620
Wiring diagram WD902.....623
Wiring diagram WD903.....626
Wiring diagram, electrical distribution box.....629
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....632
Information display, general.....633
Information display, start lockout.....635
Service mode, description.....637
39 - MISCELLANEOUS.....644
CareTrack W-ECU, description.....645
004 - POWER TRANSMISSION.....649
40 - GENERAL.....650
Power transmission, description.....651
42 - TRANSMISSION; HYDRAULIC CONTROL.....653
Induction sensor for output shaft, replacing.....654
44 - HYDROSTATIC DRIVE.....656
Hydraulic diagram transmission.....657
Hydraulic motor, replacing.....660
Hydraulic pump coupling, description.....665
Hydraulic pump, replacing .....667
Hydrostatic pump charge pressure, checking and adjusting.....673
Hydrostatic pump cut off valve, checking and adjusting.....675
Hydrostatic pump mechanical zero position, checking and adjusting.....678
Hydrostatic pump, description.....681
Power transmission, specifications.....684
Shaft seal replacing.....685
Start hydraulic pump control, checking and adjusting.....688
Travel motor, description.....691
46 - FRONT AXLE; REAR AXLE.....694
Axle, installing.....695
Axle, removing.....699
Axles and propeller shaft, tightening torque.....703
Drive axles, description.....704
Front axle, installing.....705
Front axle, removing.....708
Front axle, specifications.....711
Rear axle, specifications.....712
005 - BRAKE.....713
50 - GENERAL.....714
Brakes, specifications.....715
Description brake system.....716
Troubleshooting and actions to fix problems.....718
51 - WHEEL BRAKE.....720
Brake disc, replacing one.....721
Brake system, bleeding .....725
52 - HYDRAULIC BRAKE SYSTEM.....727
Brake pads, replacing_{02-46-10}.....728
Brake pads, replacing_{02-46-11}.....731
Brake system, bleeding.....735
006 - STEERING.....737
60 - GENERAL.....738
Steering system, description.....739
Steering unit, specification.....741
Steering, tightening torques.....742
64 - STEERING.....743
Hydraulic diagram, steering.....744
Steering pressure, checking.....746
Steering valve solenoid, replacing.....748
Steering wheel, tightening torques.....752
Troubleshooting and actions to fix problems.....754
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....757
70 - GENERAL.....758
Frame and track unit, description.....759
Frame, weight.....760
71 - FRAME.....761
Counterweight, installing.....762
Counterweight, removing.....765
74 - FRAME LINK.....768
Frame joint, Replacing the front pivot bearing with machine separated.....769
Frame joint, assembly of separated machine.....771
Frame joint, replacing the rear pivot bearing with machine separated.....779
Frame joint, separating machine.....781
Steering joint, tightening torques.....790
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....791
Tire size.....792
Wheel, tightening torque.....794
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....795
80 - GENERAL.....796
Cab description.....797
81 - CAB, NAKED; CANOPY.....798
Cab mounts, tightening torques.....799
Cab, installing.....800
Cab, removing.....809
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....819
Engine hood, installing.....820
Engine hood, removing.....822
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.....824
Rear window, replacing.....825
Windows, general.....828
Windscreen, replacing.....829
87 - AIR CONDITIONING UNIT.....832
Air conditioning unit, maintenance.....833
Air conditioning, capacity.....835
Combination sensor, check.....836
Cooling unit, leak detection.....838
Diesel heater, description.....840
Diesel heater, principles.....843
Diesel heater, specifications.....844
Disassembly and assembly.....846
Electrical schematic.....851
Error code, troubleshooting.....854
Fault mode diagnosis.....857
Heating system, description.....859
Refrigerant, draining.....862
Refrigerant, filling incl vacuum pumping.....864
Symptom_malfunction.....867
Troubleshooting, air conditioning unit (AC).....869
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....873
90 - GENERAL.....874
Cleanliness when working on hydraulic components.....875
General information to note when working on the hydraulic system.....876
Hydraulic components, storing and transporting.....878
Hydraulic oil, storage and handling.....879
Hydraulic system, repair of hydraulic components in workshop.....880
Troubleshooting chart.....882
Vacuum pump, connection.....885
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....887
Boom Suspension System, general description.....888
Hydraulic diagram, Boom Suspension System.....891
Hydraulic diagram, control valve.....893
Hydraulic oil cooler, replacing.....895
Hydraulic oil tank, installing.....897
Hydraulic oil tank, removing.....900
Hydraulic pump, replacing.....904
Hydraulic pumps, description.....907
Hydraulic system, description.....908
Hydraulic system, specification.....909
Hydraulic system, volume.....910
Main control valve, description.....911
Main control valve, installing.....913
Main control valve, removing.....916
Primary pressure limiting valve, checking and adjusting.....919
Secondary pressure limiting valve, checking and adjusting.....923
Secondary pressure limiting valve, replacing.....927
Working hydraulics, tightening torques.....930
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....931
Implemental attachment hydraulic cylinder, replacing.....932
94 - UNIT, LOAD HANDLING.....936
Hydraulic cylinder creeping, checking.....937
Lift cylinder, replacing.....939
Tilt cylinder, replacing.....944
Tilting and lifting cylinders.....948
99 - MISCELLANEOUS.....951
3rd hydraulic function - image 1.....952
3rd hydraulic function - image 2.....953
3rd hydraulic function.....954
Additional pump - image.....958
Additional pump.....959
Flow control for 3rd hydraulic function - image 1.....962
Flow control for 3rd hydraulic function - image 2.....963
Flow control for 3rd hydraulic function.....964
Hydraulic diagram with option components - image.....972
Hydraulic diagram with option components.....973
Hydraulic diagram, line rupture valves - images.....976
Hydraulic diagram, line rupture valves.....977
Hydraulic diagram, working hydraulic system.....980
Hydraulic function, 4th switchable from 3rd.....984
