Volvo L20B Compact Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L20B Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Volvo L20B 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 L20B Compact Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 626 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
Air conditioning, capacity_{12-00-21}.......7
Air conditioning, capacity_{12-00-33}.......8
Axles and propeller shaft, tightening torque.......9
Axles, specifications.......10
Brake, specifications.......11
Brakes, tightening torques.......12
Conversion tables.......13
Damper weight, weight .......21
Electrical system, specifications-.......22
Front axle, capacities.......23
Front axle, weight.......24
Hydraulic system, capacities-[0102].......25
Hydraulic system, specification.......26
Power transmission, specifications-.......27
Rear axle, capacity.......28
Rear axle, weight.......29
Steering unit, specification.......30
Steering, tightening torques_{12-01-32}.......31
Steering, tightening torques_{12-01-44}.......32
Travel hydraulics hydrostatic pump, tightening torque.......33
Volvo standard tightening torques.......34
Working hydraulics, tightening torques.......37
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION.......38
Transporting the machine.......39
07 - STANDARD TIME.......41
Operation numbers for additional work.......42
08 - TOOL.......44
E-tool Cab support.......45
E-tool Guide bolts.......46
E-tool Sleeve.......47
09 - MISCELLANEOUS.......48
Service positions.......49
1 - STANDARD PARTS, SERVICE.......50
16 - LUBRICANT; FUEL; OTHER FLUID.......51
Alternative fuels.......52
Recommended lubricants.......55
17 - SERVICE.......57
Air cleaner primary filter, change.......59
Air cleaner secondary filter, change.......61
Arrival Inspection, according to Inspection Programme.......62
Axles, changing oil.......63
Battery, cables and connections, check.......66
Bolted joints, check tightening torque.......67
Brake fluid level, check.......68
Cab filter, replace (clean when necessary)_{011-42-05}.......69
Cab filter, replace (clean when necessary)_{011-42-18}.......71
Charging batteries.......73
Cleanliness, braking and hydraulic system.......74
Delivery Inspection, according to Inspection Programme.......75
Delivery Instructions, according to Inspection Programme.......76
Electric welding.......77
Engine radiator and hydraulic oil cooler, check (clean when necessary).......78
Engine, oil level, check.......80
Fuel filters, primary and secondary filter, replace.......81
Hydraulic oil filter, changing.......83
Hydraulic oil level, check.......85
Hydraulic pressure, checking.......86
Low and high idle, checking.......87
Lubrication.......88
Maintenance of Stored Machines, according to Inspection Programme.......90
Maintenance service, daily.......91
Maintenance service, every 100 hours.......92
Maintenance service, every 1000 hours.......93
Maintenance service, every 1500 hours.......95
Maintenance service, every 2000 hours.......96
Maintenance service, every 4000 hours.......98
Maintenance service, every 500 hours.......100
Maintenance service, every 6000 hours.......101
Maintenance service, general.......103
Service brake, brake pads, checking.......104
Service position 001_{11-52-45}.......105
Service position 002_{11-52-59}.......107
Steering cylinders, locking of pivot pins, checking.......109
Steering pressure, checking.......110
Test-run and check.......111
The machine, check for external damages, cracks and wear damages.......112
Towing a disabled machine.......113
Tyres, wear and air pressure, checking.......115
Valve clearance, checking and adjusting.......116
Water separator, drain.......117
Wheel nuts torque, checking.......118
Work on the machine's electrical system.......119
19 - GENERAL.......120
CE-marking, EMC-directive.......121
Checklist after a fire or heat exposure.......125
Decontamination.......126
Environmental handling for the future.......128
Environmentally hazardous fluids.......130
Environmentally safe handling.......131
Fire prevention measures.......133
Health hazards with paint, plastics and rubber.......136
Loader boom, safety strut.......138
Safety concerns everybody!.......141
Safety rules when servicing.......143
Safety when handling accumulators.......146
Safety when handling oils and fuel.......147
Safety when handling the machine.......148
Safety when working on hydraulic systems.......152
Safety when working with batteries.......154
Safety when working with refrigerant.......157
Service position 001_{11-36-53}.......160
Service position 001_{11-37-31}.......162
Service position 002_{11-37-07}.......164
Service position 002_{11-37-45}.......166
Some simple rules regarding tyre handling.......168
Starting with booster batteries.......170
Waste handling.......172
Working in environmentally contaminated areas.......173
Working under raised boom.......174
2 - ENGINE WITH MOUNTING AND EQUIPMENT.......175
20 - GENERAL.......176
Engine, capacities.......177
Engine, description.......178
Engine, weights.......182
21 - ENGINE.......183
Belt, changing.......184
Camshaft, description.......197
Crankshaft, description.......199
Cylinder compression, testing.......200
Cylinder head, description.......203
Engine, installing.......204
Engine, removing.......212
Engine, specifications_{011-28-21}.......220
Engine, specifications_{011-28-33}.......224
Valve mechanism, description.......228
Valves, adjusting.......229
22 - LUBRICATING SYSTEM.......233
Lubrication system, description.......234
Oil pump, description.......236
23 - FUEL SYSTEM.......238
Fuel feed pump, description.......239
Fuel filters, replacing.......240
Fuel pump, installing.......242
Fuel pump, removing.......244
Fuel system, description.......246
Fuel tank, capacities.......248
Idling speed, checking and adjusting.......249
Injection valve, check.......253
25 - INLET & EXHAUST SYSTEM.......256
Air filter, description.......257
Air filter, technical data.......258
EGR (exhaust gas recirculation) sensor, replacing.......259
Exhaust manifold gasket, replacing.......265
26 - COOLING SYSTEM.......267
Cooling system, description.......268
Fan belt and_or alternator belt, replacing.......269
Radiator, installing.......272
Radiator, removing.......274
Thermostat, replacing.......276
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......280
30 - GENERAL.......281
Electrical system, description.......282
Electrical system, instructions.......284
Electrical system, specifications.......285
31 - BATTERY.......286
Battery, charging.......287
Battery, description.......289
32 - ALTERNATOR; CHARGE REGULATOR.......290
Alternator, installing.......291
Alternator, removing.......296
33 - STARTING SYSTEM.......300
Air preheating, description.......301
Starter motor, replacing.......302
35 - LIGHTING.......304
Overview lighting, devices.......305
36 - OTHER ELECTRICAL EQUIPMENT.......307
Instrument panel, electrical circuit.......308
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......310
Cable markings.......311
Electrical components, engine side, description.......313
Instrument panel, description.......315
Relays and fuses in electrical distribution box.......317
Relays and fuses in engine compartment.......323
Wiring diagram 001.......324
Wiring diagram 002.......328
Wiring diagram 003.......332
Wiring diagram 004.......337
Wiring diagram 005.......341
Wiring diagram 006.......345
Wiring diagram 007.......348
Wiring diagram 008.......351
Wiring diagram 009.......354
Wiring diagram 010.......357
Wiring diagram 011.......360
Wiring diagram 012.......363
Wiring diagram 013.......366
Wiring diagram 014.......369
Wiring diagram 015.......372
Wiring diagram 016.......375
Wiring diagram 017.......377
Wiring diagram 018.......380
Wiring diagram 019.......383
Wiring diagram, figure text.......386
4 - POWER TRANSMISSION.......393
40 - GENERAL.......394
Power transmission, description.......395
Troubleshooting and actions to fix problems.......397
Troubleshooting chart-.......398
42 - TRANSMISSION; HYDRAULIC CONTROL.......402
Induction sensor for output shaft, replacing_{010-54-06}.......403
Induction sensor for output shaft, replacing_{010-54-19}.......405
44 - HYDROSTATIC DRIVE.......407
Hydraulic diagram transmission.......408
Hydraulic motor, replacing.......411
Hydraulic pump coupling, description.......416
Hydraulic pump, replacing.......418
Hydrostatic pump charge pressure, checking and adjusting.......425
Hydrostatic pump cut off valve, checking and adjusting.......427
Hydrostatic pump mechanical zero position, checking and adjusting.......430
Hydrostatic pump, description.......433
Power transmission, specifications.......436
Start hydraulic pump control, checking and adjusting.......437
Travel motor, description.......441
46 - FRONT AXLE; REAR AXLE.......444
Axle, installing.......445
Axle, removing.......449
Drive axles, description.......453
5 - BRAKE.......455
50 - GENERAL.......456
Brake design.......457
Description brake system.......459
Troubleshooting and actions to fix problems-.......461
51 - WHEEL BRAKE.......463
Brake cylinder, replacing.......464
Brake pads, replacing.......467
52 - HYDRAULIC BRAKE SYSTEM.......474
Brake system, bleeding.......475
Inching and brake pedal, adjusting.......477
6 - STEERING.......479
60 - GENERAL.......480
Steering system, description.......481
Steering, tightening torques.......483
64 - STEERING.......484
Hydraulic diagram, steering.......485
Steering system working pressure, checking and adjusting.......487
Steering valve, installing.......489
Steering valve, removing.......492
Troubleshooting and actions to fix problems-.......495
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......497
71 - FRAME.......498
Damper weight, weight.......499
Frame L020B, weights.......500
Frame, description.......501
Frame, design.......502
74 - FRAME LINK.......504
Frame joint, Replacing the front pivot bearing with machine separated.......505
Frame joint, assembly of separated machine.......507
Frame joint, replacing the rear pivot bearing with machine separated.......514
Frame joint, separating machine.......516
Steering joint, tightening torques.......525
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......526
Hydraulic system, capacities.......527
Wheels, tightening torques.......528
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......529
81 - CAB, NAKED; CANOPY.......530
Cab mounts, tightening torques.......531
Repairs of minor damage on internal and external plastic parts (scratches, dents, breaks).......533
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......535
Rear window, replacing.......536
Windows, general.......539
Windscreen, replacing.......540
87 - AIR CONDITIONING UNIT.......543
Air conditioning, capacity.......544
Combination sensor, check.......545
Diesel heater, description.......547
Diesel heater, principles.......550
Diesel heater, specifications.......551
Disassembly and assembly.......553
Electrical schematic.......558
Error code, troubleshooting.......561
Fault mode diagnosis.......564
Symptom_malfunction.......566
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......568
90 - GENERAL.......569
Cleanliness when working on hydraulic components.......570
General information to note when working on the hydraulic system.......571
Hydraulic components, storing and transporting.......573
Hydraulic oil, storage and handling.......574
Hydraulic system, repair of hydraulic components in workshop.......575
Troubleshooting chart.......577
Vacuum pump, connection.......580
91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......582
Boom Suspension System, description.......583
Hydraulic diagram working hydraulics.......585
Hydraulic diagram, Boom Suspension System.......588
Hydraulic diagram, control valve.......590
Hydraulic oil tank, description.......592
Hydraulic pumps, description.......594
Hydraulic system, description.......595
Main control valve, description.......596
Primary pressure limiting valve, checking and adjusting.......598
Secondary pressure limiting valve, checking and adjusting.......601
Working hydraulic system, component location.......604
92 - MECHANICAL EQUIPMENT_ATTACHMENT.......606
Hydraulic attachment bracket (quickfit), description.......607
Implemental attachment hydraulic cylinder, replacing.......608
Lock cylinder.......612
94 - UNIT, LOAD HANDLING.......614
Lift cylinder, replacing.......615
Tilt cylinder, replacing.......620
Tilting and lifting cylinders.......624
Volvo L20B Compact Wheel Loaders Repair Service Manual
