Volvo DD138HA DD138HF DD138HFA Asphalt Compactor Workshop Repair Manual PDF - MVLVCONDD138.zip
A full-service repair manual, complete with Electrical Wiring Diagrams, for the Volvo DD100 Asphalt Compactor — containing every technical detail needed to maintain, troubleshoot, and fix the machine just like a trained technician.
This workshop service and repair manual for the Volvo Construction Equipment DD100 Asphalt Compactor covers:
* 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.
Asphalt Compactors Volvo DD138HFA Service Repair Manual.pdf
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; 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 EQUIPM.; MISC EQUIPM
PRODUCT DETAILS:
Total Pages: 713
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description; complete machine...4
Location of components...7
Machine identification...9
Operator' protective structure; component locations...11
03 - SPECIFICATIONS...13
Specifications; general_03-05...14
Specifications; general...15
Tightening torque; specifications_{02-22}...16
Tightening torque; specifications_{02-00}...19
Tightening torque; specifications_{01-39}...21
Tightening torque; specifications_{01-17}...23
Conversion tables...26
Thread locking compound; application_specifications...34
Hydraulic oil; specifications_59-49...37
Lubrication and oil system; general specifications_59-24...39
Engine; specifications...41
Critical mounting torques...42
Machine dimensions...44
Machine weight; specifications...46
Recommended lubricants_57-26...47
Electrical system; specifications...50
Battery; specifications...51
Power transmission; specifications...52
Brake system; specifications...53
Drum; specifications...54
Hydraulic pump; specifications...56
Hydraulic motor; specifications_54-45...58
Hydraulic connections; tightening torques_{54-17}...60
Hydraulic connections; tightening torques_{53-52}...63
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...70
Travelling on public road...71
Transporting the machine...72
07 - STANDARD TIME...74
Operation numbers for additional work...75
1 - STANDARD PARTS; SERVICE...77
16 - LUBRICANT; FUEL; OTHER FLUID...78
Hydraulic oil; specifications...79
Alternative fuels...81
Oil and filtration ...84
Lubricant recommendation...86
Environmentally safe handling ...87
Recommended lubricants...89
Lubrication and oil system; general specifications...92
Fuel; lubricant and filling capacities...94
17 - SERVICE...95
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...97
Towing a disabled machine...99
Starting with booster batteries...100
Water filter; changing ...102
Water tank and spray bars; drain and flush...104
Water tank level; checking...107
Water pump strainer; checking...109
Hydraulic oil filter; replacing...111
Breather; replacing...113
Hydraulic oil suction strainer; cleaning...115
Hydraulic oil; changing...118
Hydraulic system; checking oil level...121
Drum carrier; changing oil...123
Drum shock mount; replacing ...126
Drum shock mounts; checking...128
Drum eccentric; changing oil...130
Drum eccentric; checking oil level...132
Drum; checking...134
Swivel joint (horizontal and vertical) pins; torque...136
Parking brake performance...137
Battery disconnect switch (main switch); check...139
Battery maintenance...140
Radiator and coolers; cleaning...141
Coolant; changing...143
Coolant level; check...146
Fan belt; check...148
Coolant mixture...150
Engine; air cleaner maintenance...151
Air cleaner; secondary filter replacing...153
Air cleaner; primary filter replacing...156
Fuel; coolant and oil leaks; checking...159
Fuel filters; replacing...160
Fuel line; water separator; check and drain...162
Fuel system; bleeding...164
Engine oil and filter; changing...166
Engine oil level; check...168
Maintenance service; first 50 hours...170
Maintenance service; every 6000 hours...171
Maintenance service; every 3000 hours...172
Maintenance service; every 2000 hours...173
Maintenance service; every 1000 hours...174
Maintenance service; every 500 hours...175
Maintenance service; every 50 hours...176
Maintenance service; every 10 hours...177
Maintenance of Stored Machines; according to Inspection Programme...178
Delivery Inspection; according to Inspection Programme...179
Arrival Inspection; according to Inspection Programme...180
19 - GENERAL...181
Towing procedures...183
Environmental requirements...186
Fire prevention measures...187
Safety when working on hydraulic system...191
Safety when lifting and supporting complete machine...193
Decontamination...195
Environmental handling for the future...199
Environment...202
Safety when lifting and supporting the machine...207
Charging batteries...210
Safety when working with batteries...214
Safety when handling oil and fuel...217
Health hazards with paint; plastics and rubber...220
Checklist after a fire or heat exposure...224
Electrical system...227
Cleanliness...231
General...235
Before service; read...240
Before operating...244
A few simple safety rules...248
Safety when handling the machine...252
Handling hazardous materials...256
Health hazards with paint; plastics and rubber ...259
Environmentally safe handling...262
Safety when working on the electrical system...265
Check list after fire or heat exposure...267
Safety when servicing...269
Stopping...272
Safe operation of the machine...273
Safety when handling the machine ...278
Service position...281
Safety concerns everybody!...283
2 - ENGINE WITH MOUNTING AND EQUIPMENT...287
20 - GENERAL...288
Engine; description...289
Low engine oil pressure...290
Engine overheated...291
Heavy exhaust smoke development...292
Engine difficult to start...293
Engine does not start...294
21 - ENGINE...296
Engine; removing...297
Engine; installing...303
Engine mounts; replacing...309
23 - FUEL SYSTEM...312
Fuel tank; description...313
25 - INLET & EXHAUST SYSTEM...315
Silencer; replacing...316
Air cleaner; removing...318
Air cleaner; installing...320
Air cleaner; description...322
Charge air cooler; description...325
Charge air cooler; removing...327
Charge air cooler; installing...329
Charge air cooler pipe; removing...331
Charge air cooler pipe; installing...332
26 - COOLING SYSTEM...333
Cooling system; description...334
Radiator; replacing...336
Fan belt and_or alternator belt; replacing...342
Fan shroud; replacing...343
Cooling fan; replacing...346
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...349
30 - GENERAL...350
Fault code 3-4-3 – Front eccentric VPM and drum speed sensors circuit...352
Fault code 3-4-2 – Front eccentric VPM sensor circuit...353
Fault codes 3-3-5 and 3-4-1 – Impact spacing meter circuit...355
Fault code 3-3-3 – Troubleshooting circuit...357
Fault codes 3-3-2 and 3-3-4 – Vibration ON lamp circuit...358
Fault code 3-3-1 – Rear VIB REV_CCW solenoid circuit...360
Fault code 3-2-5 – Rear VIB REV_CCW solenoid circuit...362
Fault code 3-2-4 – Rear VIB FWD_CW solenoid circuit...364
Fault code 3-2-3 – Rear VIB FWD_CW solenoid circuit...366
Fault code 3-2-2 – Front VIB REV_CCW solenoid circuit...368
Fault code 3-2-1 – Front VIB REV_CCW solenoid circuit...370
Fault Code 3-1-5 – Front VIB FWD_CW Solenoid Circuit...372
Fault code 3-1-4 – Front VIB FWD_CW solenoid circuit...374
Fault code 3-1-3 – Impact spacing_auto threshold circuit...376
Fault code 3-1-2 – Eccentric drum select switch circuit...378
Fault code 3-1-1 – Eccentric drum direction switch circuit...380
Fault code 2-4-1 – Engine running input circuit...382
Fault code 2-3-5 – Park brake command switch circuit...384
Fault codes 2-3-4 – Park brake test circuit...386
Fault codes 2-3-2 and 2-3-3 – Operator absent circuit...387
Fault codes 2-2-5 and 2-3-1 – Park brake release circuit...389
Fault codes 2-2-3 and 2-2-4 – High throttle pull circuit...391
Fault codes 2-2-1 and 2-2-2 – Drive enable circuit...393
Fault codes 2-1-4 and 2-1-5 – High throttle hold circuit...395
Fault code 2-1-3 – Fuel solenoid release circuit...397
Fault code 2-1-1 and 2-1-2 – Fuel solenoid release circuit...399
Fault code 1-2-4 and 1-2-5 – System status lamp circuit...401
Fault code 1-2-3 – Machine model input circuit...403
Fault code 1-2-2 – Machine type input circuit...405
Fault codes 1-1-5 and 1-2-1 – Sensor voltage #2 circuit...407
Fault codes 1-1-4 – Sensor voltage #1 circuit...409
Fault code 1-1-3 – Sensor voltage #1 circuit...411
Fault codes 1-1-1 and 1-1-2 – System voltage circuit...413
Vibration controls not functioning...415
Multi-pin breakout box; connecting...416
Electrical troubleshooting...419
Low voltage...430
Troubleshooting; general...431
31 - BATTERY...433
Batteries; replacing...434
32 - ALTERNATOR; CHARGE REGULATOR...436
Alternator; installing...437
Alternator; removing...439
Alternator; description...441
33 - STARTING SYSTEM...443
Starter switch (engine start switch); replacing...444
Starter motor; replacing...447
Starter motor; description...449
36 - OTHER ELECTRICAL EQUIPMENT...451
Electric and hydraulic control unit; replacing...452
Instruments and controls; overview...454
Control unit; description...458
Connectors; position_{26-44}...460
Connectors; position_{27-05}...463
Reverse alarm; replacing...466
37 - CABLE; FUSE; RELAY...467
Electrical components; engine side...468
Component list; fuses...470
Cable; Battery isolation switch...472
Wiring diagram 3...473
Wiring diagram 2...475
Wiring diagram 1...477
Component list; relays...479
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...480
Fuel level sender; replacing...481
4 - POWER TRANSMISSION...483
40 - GENERAL...484
Power Transmission; Propulsion...485
Smart functions; description...489
Power train; troubleshooting...490
42 - TRANSMISSION; HYDRAULIC CONTROL...498
Pump de-stroke valve and solenoid; description...499
Multi-function brake valve; description ...500
Multi function brake valve solenoid and cartridge; replacing ...502
Parking brake pressure switch; replacing ...504
Two speed valve solenoid and cartridge; replacing...506
44 - HYDROSTATIC DRIVE...508
Hydrostatic controller; removing...509
Hydrostatic controller; installing...510
Hydraulic motor; specifications ...512
Drum drive motor; description...514
Drive motor; removing...517
Drive motor; installing...519
Hydrostatic pump; description...521
Hydrostatic pump; removing...523
Pump coupling; removing...525
Pump coupling; installing...527
Hydrostatic pump; installing...529
Loop flushing valve; description...531
Loop flushing valve; replacing...534
Drum drive motor speed sensor; replacing...536
5 - BRAKE...538
52 - HYDRAULIC BRAKE SYSTEM...539
Hydraulic brake system; description...540
55 - PARKING BRAKE...541
Multi-function brake valve; description...542
Multi function brake valve solenoid and cartridge; replacing...544
Parking brake pressure switch; replacing...546
6 - STEERING...548
60 - GENERAL...549
Steering system; specifications...550
Steering system; description...552
Steering system; troubleshooting...554
64 - STEERING...560
Adjustable steering column; replacing...561
Steering control unit; removing...565
Steering control unit; installing...568
Steering pressure; checking and adjusting...570
Steering cylinder; replacing...572
Hydraulic pump; replacing...574
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...576
71 - FRAME...577
Frame; description...578
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...580