To begin the rebuilding process, it is essential to gather all the necessary tools and equipment.
These typically include a socket set, wrenches, pliers, a brake cleaner, replacement seals and gaskets, and a service manual specific to the L120 model.
The first step is to disconnect the machine's battery to ensure safety during the rebuilding process. Next, locate the servo brake pump, which is usually positioned near the engine or the braking system. Carefully remove the pump from its mounting position, taking note of any electrical connections or hoses that need to be disconnected.
Once the servo brake pump is removed, inspect it thoroughly for any signs of damage, wear, or leaks. Pay close attention to the pump's housing, pistons, seals, and gaskets. If any of these components are damaged or worn beyond their specifications, they should be replaced with new ones.
Using the service manual as a guide, disassemble the servo brake pump, taking care to note the exact positioning of each component. Clean all the parts with a brake cleaner to remove any dirt, debris, or old brake fluid. Inspect the pistons and cylinders for any signs of scoring or excessive wear. If necessary, replace these components to ensure optimal performance.
Once the pump and its components are clean and inspected, it is time to rebuild the servo brake pump. Begin by installing new seals and gaskets according to the manufacturer's specifications. Ensure that each seal is correctly positioned and properly lubricated with brake fluid to prevent leaks.
Carefully reassemble the pump, following the reverse order of disassembly. Take care not to overtighten any bolts or fittings, as this can cause damage to the pump or its components. Once the pump is fully reassembled, reinstall it in its original mounting position, reconnecting any hoses or electrical connections that were previously disconnected.
After the servo brake pump is securely reinstalled, it is important to bleed the braking system to remove any air trapped in the lines.
Follow the recommended bleeding procedure outlined in the service manual to ensure proper brake function.
Finally, before putting the Volvo L120 back into operation, test the servo brake pump for any leaks, unusual noises, or malfunctions. Engage the brakes several times to ensure they are responsive and effective. Monitor the brake fluid level and top up if necessary.
