Volvo PT220 PT220 RH Asphalt Compactor Workshop Repair Service Manual PDF - MVLVCONPT220.zip

Full service and repair documentation, complete with electrical wiring schematics, covering the Volvo Construction Asphalt Compactors PT220 and PT220 RH — everything needed to maintain, troubleshoot, and overhaul these machines to the same standard as factory-trained technicians.

The workshop service and repair manual for the Volvo PT220 and PT220 RH Asphalt Compactors contains:

* 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