Volvo L20F Compact Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L20F Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo L20F Compact Wheel Loaders 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.
Volvo L20F Compact Wheel Loaders Service Repair Manual.pdf.pdf
PRODUCT DETAILS:
Total Pages: 807 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword.....2
0 - GENERAL.....3
00 - DESCRIPTION; COMPLETE MACHINE.....4
Description.....5
03 - SPECIFICATIONS.....6
Conversion tables.....7
Measurement conversion Tables.....15
Measurement conversion tables.....20
Oil pump, description.....24
Volvo standard tightening torques_{12-44-47}.....26
Volvo standard tightening torques_{12-44-59}.....29
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.....31
Transporting the machine.....32
07 - STANDARD TIME.....34
Operation numbers for additional work.....35
08 - TOOL.....37
E-tool Cab support.....38
E-tool Guide bolts.....39
E-tool Sleeve.....40
09 - MISCELLANEOUS.....41
Service positions.....42
1 - STANDARD PARTS, SERVICE.....43
16 - LUBRICANT; FUEL; OTHER FLUID.....44
Alternative fuels.....45
Recommended lubricants.....48
17 - SERVICE.....50
Arrival Inspection, according to Inspection Programme.....52
Axle oil, changing.....53
Battery, checking.....56
Brake fluid level, checking.....57
Cab main filter, replacing.....58
Charging batteries.....60
Cleanliness, braking and hydraulic system.....61
Delivery Inspection, according to Inspection Programme.....62
Delivery Instructions, according to Inspection Programme.....63
Electric welding.....64
Engine air cleaner primary filter, replacing.....65
Engine air cleaner secondary filter, replacing.....67
Engine oil and filter, changing.....69
Engine oil level, checking.....71
Fan_alternator belt, checking.....72
Fuel filters, replacing.....74
Hydraulic oil filters, replacing.....76
Hydraulic oil level, checking.....78
Hydraulic oil, changing.....80
Hydraulic pressure, checking.....82
Low and high idle, checking.....90
Lubrication.....94
Maintenance of Stored Machines, according to Inspection Programme.....96
Maintenance service, every 10 hours.....97
Maintenance service, every 100 hours.....98
Maintenance service, every 1000 hours.....99
Maintenance service, every 1500 hours.....101
Maintenance service, every 2000 hours.....102
Maintenance service, every 3000 hours.....104
Maintenance service, every 5000 hours.....106
Radiator and hydraulic oil cooler, cleaning.....107
Service and maintenance.....109
Service brake pads, checking.....111
Service position 001_{12-35-54}.....112
Service position 002_{12-36-10}.....114
Steering cylinders, locking of pivot pins, checking.....116
Steering pressure, checking .....117
Test running and checking.....119
Towing a disabled machine.....120
Tyre wear and air pressure, checking.....122
Valves, adjusting .....123
Water separator, checking.....127
Wheel nuts torque, checking.....128
Work on the machine's electrical system.....129
19 - GENERAL.....130
CE-marking, EMC-directive.....131
Checklist after a fire or heat exposure.....135
Decontamination.....136
Environmental handling for the future.....138
Environmentally hazardous fluids.....140
Environmentally safe handling.....141
Fire prevention measures.....143
Health hazards with paint, plastics and rubber.....146
Loader boom, safety strut.....148
Safety concerns everybody!.....151
Safety rules when servicing.....153
Safety when handling accumulators.....156
Safety when handling oils and fuel.....157
Safety when handling the machine.....158
Safety when lifting and supporting complete machine.....162
Safety when using lifting equipment.....164
Safety when working on hydraulic systems.....166
Safety when working with batteries.....168
Safety when working with refrigerant.....171
Service position 001_{12-20-01}.....174
Service position 002_{12-20-18}.....176
Some simple rules regarding tyre handling.....178
Starting with booster batteries.....180
Waste handling.....182
Working in environmentally contaminated areas.....183
Working under raised boom.....184
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....185
20 - GENERAL.....186
Engine, capacities.....187
Engine, description_{012-11-37}.....188
Engine, description_{012-11-53}.....192
Engine, tightening torques.....195
Engine, weight.....197
21 - ENGINE.....198
Belt, changing.....199
Camshaft, description.....212
Crankshaft, description.....214
Cylinder compression, testing.....215
Cylinder head, description.....218
Engine, installing.....219
Engine, removing.....227
Engine, specifications_{012-09-48}.....235
Engine, specifications_{012-09-59}.....236
Valve mechanism, description.....237
Valves, adjusting.....238
22 - LUBRICATING SYSTEM.....242
Lubrication system, description.....243
Oil cooler, replacing.....245
Oil pump, description.....249
Oil pump, replacing.....251
23 - FUEL SYSTEM.....254
Fuel feed pump, description.....255
Fuel pump, installing.....256
Fuel pump, removing.....258
Fuel system, description.....260
Fuel tank level sensor, replacing_{011-57-02}.....262
Fuel tank level sensor, replacing_{011-57-15}.....265
Fuel tank, capacities.....268
Fuel tank, installing.....269
Fuel tank, removing.....276
Idling speed, checking and adjusting.....284
Injection pump, removing.....288
Injection valve, check.....301
Injectors, replacing.....304
25 - INLET & EXHAUST SYSTEM.....309
Air filter, description.....310
EGR (exhaust gas recirculation) sensor, replacing.....311
Exhaust manifold gasket, replacing.....317
26 - COOLING SYSTEM.....319
Cooling system, description.....320
Fan belt and_or alternator belt, replacing.....321
Thermostat, replacing.....324
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....328
30 - GENERAL.....329
Automatic engine shut-down.....330
Electrical system, description.....331
Electrical system, specifications.....333
Electrical system, work instructions.....334
31 - BATTERY.....335
Battery, charging.....336
Battery, description.....338
32 - ALTERNATOR; CHARGE REGULATOR.....339
Alternator, installing.....340
Alternator, removing.....345
Alternator, testing.....349
33 - STARTING SYSTEM.....351
Air preheating, description.....352
Starter motor, replacing.....353
35 - LIGHTING.....355
Lighting, description.....356
Overview lighting, devices.....358
36 - OTHER ELECTRICAL EQUIPMENT.....360
Instrument panel, electrical circuit.....361
Marking connectors_cables.....363
Windscreen wiper front motor, replacing.....365
37 - CABLE; FUSE; RELAY.....371
Cable markings.....373
Component list Alternator, batteries, capacitors, electronic units, voltage outlet.....375
Component list Fuses_{011-38-25}.....376
Component list Fuses_{011-38-53}.....381
Component list Heating coils, instruments, service socket.....386
Component list Lights.....387
Component list PWM valves.....389
Component list Relays.....390
Component list Solenoid valves.....392
Component list Switches.....393
Component list, Sounders.....395
Component list, motors.....396
Component list, sensors.....397
Connector I_O description_{011-34-42}.....398
Connector I_O description_{011-35-01}.....404
Table of contents, wiring diagrams.....411
Wiring diagram 001_{11-33-45}.....412
Wiring diagram 001_{11-34-03}.....416
Wiring diagram 002.....419
Wiring diagram 003.....422
Wiring diagram 004.....426
Wiring diagram 005.....429
Wiring diagram 006.....434
Wiring diagram 007.....437
Wiring diagram 008.....440
Wiring diagram 009.....443
Wiring diagram 010.....446
Wiring diagram 011.....449
Wiring diagram 012.....452
Wiring diagram 013.....455
Wiring diagram 014.....458
Wiring diagram 015.....462
Wiring diagram 016.....466
Wiring diagram 017.....469
Wiring diagram 018.....472
Wiring diagram 019.....476
Wiring diagram 020.....478
Wiring diagram 021.....481
Wiring diagram 022.....484
Wiring diagram 023.....487
Wiring diagram 024.....489
Wiring diagram 025_{11-23-55}.....492
Wiring diagram 025_{11-24-08}.....494
Wiring diagram 025_{11-24-24}.....496
Wiring diagram 026.....498
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....501
Instrument panel, description.....502
4 - POWER TRANSMISSION.....504
40 - GENERAL.....505
Power transmission, description.....506
Troubleshooting and actions to fix problems-.....508
Troubleshooting chart-.....509
42 - TRANSMISSION; HYDRAULIC CONTROL.....513
Induction sensor for output shaft, replacing.....514
44 - HYDROSTATIC DRIVE.....516
Hydraulic diagram transmission.....517
Hydraulic motor, replacing.....520
Hydraulic pump coupling, description.....525
Hydraulic pump, replacing.....527
Hydrostatic pump charge pressure, checking and adjusting.....534
Hydrostatic pump cut off valve, checking and adjusting.....536
Hydrostatic pump mechanical zero position, checking and adjusting.....539
Hydrostatic pump, description.....542
Power transmission, specifications_{011-18-51}.....545
Power transmission, specifications_{011-19-02}.....546
Shaft seal replacing.....547
Start hydraulic pump control, checking and adjusting.....550
Travel hydraulics hydrostatic pump, tightening torque.....554
Travel motor, description.....555
46 - FRONT AXLE; REAR AXLE.....558
Axle, installing.....559
Axle, removing.....563
Axles and propeller shaft, tightening torque.....567
Axles, specifications.....568
Drive axles, description.....569
Front axle, capacities.....571
Front axle, installing.....572
Front axle, removing.....575
Front axle, weight.....578
Rear axle, capacity.....579
Rear axle, weight.....580
5 - BRAKE.....581
50 - GENERAL.....582
Brake design.....583
Brake, specifications.....585
Description brake system.....586
Troubleshooting and actions to fix problems.....588
51 - WHEEL BRAKE.....590
Brake cylinder, replacing.....591
Brake pads, replacing.....594
52 - HYDRAULIC BRAKE SYSTEM.....601
Brake system, bleeding.....602
Inching and brake pedal, adjusting.....604
6 - STEERING.....606
60 - GENERAL.....607
Steering system, description.....608
Steering unit, specification.....610
Steering, tightening torques.....611
64 - STEERING.....612
Hydraulic diagram, steering.....613
Steering pressure, checking.....615
Steering system working pressure, checking and adjusting.....617
Steering valve, installing.....619
Steering valve, removing.....622
Steering wheel, tightening torques.....625
Troubleshooting and actions to fix problems.....627
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....630
70 - GENERAL.....631
Frame and track unit, description.....632
Frame, weight.....634
74 - FRAME LINK.....635
Frame joint, Replacing the front pivot bearing with machine separated.....636
Frame joint, assembly of separated machine.....638
Frame joint, replacing the rear pivot bearing with machine separated.....646
Frame joint, separating machine.....648
Steering joint, tightening torques.....657
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....658
Wheel, tightening torque.....659
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....660
80 - GENERAL.....661
Cab description.....662
81 - CAB, NAKED; CANOPY.....663
Cab mounts, tightening torques.....664
Repairs of minor damage on internal and external plastic parts (scratches, dents, breaks).....666
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....668
Engine hood, installing.....669
Engine hood, removing.....671
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.....673
Rear window, replacing.....674
Windows, general.....677
Windscreen, replacing.....678
87 - AIR CONDITIONING UNIT.....681
Air conditioning, capacity.....682
Combination sensor, check.....683
Diesel heater, description.....685
Diesel heater, principles.....688
Diesel heater, specifications.....689
Disassembly and assembly.....691
Electrical schematic.....696
Error code, troubleshooting.....699
Fan motor, replacing.....702
Fault mode diagnosis.....708
Symptom_malfunction.....710
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....712
90 - GENERAL.....713
Cleanliness when working on hydraulic components.....714
General information to note when working on the hydraulic system.....715
Hydraulic components, storing and transporting.....717
Hydraulic oil, storage and handling.....718
Hydraulic system, repair of hydraulic components in workshop.....719
Troubleshooting chart.....721
Vacuum pump, connection.....724
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....726
Boom Suspension System, description.....727
Hydraulic diagram with option components-1.....729
Hydraulic diagram with option components-2.....732
Hydraulic diagram with option components-3.....734
Hydraulic diagram with option components-4.....736
Hydraulic diagram working hydraulics.....738
Hydraulic diagram, Boom Suspension System.....741
Hydraulic diagram, control valve.....743
Hydraulic oil tank, description.....745
Hydraulic oil tank, installing.....747
Hydraulic oil tank, removing.....755
Hydraulic pumps, description.....764
Hydraulic system, capacities.....765
Hydraulic system, description.....766
Hydraulic system, specification.....767
Main control valve, description.....768
Primary pressure limiting valve, checking and adjusting.....770
Secondary pressure limiting valve, checking and adjusting.....773
Working hydraulic system, component location.....776
Working hydraulics, tightening torques.....778
92 - MECHANICAL EQUIPMENT_ATTACHMENT.....779
Hydraulic attachment bracket (quickfit), description.....780
Implemental attachment hydraulic cylinder, replacing.....781
Lock cylinder.....785
Trailer hitch, specifications.....787
Trailer hitch.....789
94 - UNIT, LOAD HANDLING.....792
Hydraulic cylinder creeping, checking.....793
Lift cylinder, replacing.....796
Tilt cylinder, replacing.....801
Tilting and lifting cylinders.....805
Volvo L20F Compact Wheel Loaders Repair Service Manual
