Volvo SD115 Soil Compactor Workshop Repair Service Manual PDF - MVLVCONSD115.zip

A full workshop and repair guide for the Volvo SD115 Soil Compactor, packed with everything needed to service, troubleshoot, overhaul, and maintain the machine at a professional mechanic's level.

This service repair manual for the Volvo Construction Equipment SD115 Soil Compactor 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 - 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

TABLE OF CONTENTS

0 - Foreword.....2

0 - GENERAL.....3

03 - SPECIFICATIONS.....4

Conversion tables.....5

Coolant, specifications.....13

Critical mounting torques.....14

Hydraulic connections, tightening torques.....17

Thread locking compound, application_specifications.....22

Tightening torque, specifications_{11-24-53}.....25

Tightening torque, specifications_{11-25-17}.....28

07 - STANDARD TIME.....31

Operation numbers for additional work.....32

08 - TOOL.....34

88830095 Lifting tool user instructions.....35

88830142 Adapter user instructions.....40

88830352 Adapter user instructions.....44

E-7021.....48

1 - STANDARD PARTS, SERVICE.....50

16 - LUBRICANT; FUEL; OTHER FLUID.....51

Alternative fuels.....52

Fuel, lubricant and filling capacities_{11-17-46}.....55

Fuel, lubricant and filling capacities_{11-18-11}.....56

Recommended lubricants.....57

17 - SERVICE.....61

Arrival Inspection, according to Inspection Programme.....64

Axle breathers, cleaning_{11-00-44}.....65

Axle breathers, cleaning_{11-01-12}.....67

Axle differential and brake oil level, checking_{11-01-54}.....69

Axle differential and brake oil level, checking_{11-02-21}.....71

Axle differential and brake oil, changing_{10-44-55}.....73

Axle differential and brake oil, changing_{10-45-23}.....76

Axle wheel end oil level, checking.....80

Axle wheel end oil, changing.....82

Battery system integrity, checking.....84

Belt condition, checking.....86

Belt tensioner, checking.....88

Cab main filter, replacing.....89

Cab prefilter, replacing.....92

Cab ventilation filters, cleaning.....94

Coolant level, checking.....98

Coolant mixture, checking.....99

Coolant, draining.....101

Coolant, filling.....104

Cooling system integrity, checking.....106

Delivery Inspection, according to Inspection Programme.....107

Diesel particulate filter, check and clean_{10-38-01}.....108

Diesel particulate filter, check and clean_{10-38-30}.....115

Drum carrier breather, cleaning.....122

Drum carrier oil level, checking.....124

Drum carrier oil, draining.....126

Drum carrier oil, filling.....128

Drum eccentric oil level, checking.....129

Drum eccentric oil, draining.....131

Drum eccentric oil, filling.....133

Drum shock mount, replacing .....135

Drum shock mounts, checking.....137

Emergency stop switch, checking.....138

Engine air cleaner primary filter, cleaning.....139

Engine air cleaner primary filter, replacing.....141

Engine air cleaner secondary filter, changing.....143

Engine air cleaner system integrity, checking.....145

Engine hood, operating .....146

Engine oil and filter, changing.....148

Engine oil filter, replacing.....149

Engine oil level, checking.....151

Engine oil, draining.....153

Engine oil, filling.....155

Fuel filter, replacing.....157

Fuel system, bleeding-[3642].....159

Fuel tank breather filter, replacing.....161

Fuel_water separator, draining.....163

Horizontal swivel pin torque, checking.....164

Hydraulic oil filters, replacing.....167

Hydraulic oil level, checking.....169

Hydraulic oil suction strainer, cleaning.....170

Hydraulic oil tank, draining.....172

Hydraulic oil tank, filling.....174

Hydraulic system breather filter, replacing.....176

Maintenance of Stored Machines, according to Inspection Programme.....178

Maintenance service, daily.....179

Maintenance service, every 1000 hours.....180

Maintenance service, every 2000 hours.....182

Maintenance service, every 3000 hours.....184

Maintenance service, every 50 hours.....185

Maintenance service, every 500 hours.....187

Maintenance service, every 6000 hours.....189

Maintenance service, first 50 hours_{11-11-18}.....190

Maintenance service, first 50 hours_{11-11-42}.....191

Parking brake function, checking.....192

Planetary drive oil level, checking.....194

Planetary drive oil, changing.....196

Radiator and coolers, cleaning.....198

Ratchet jack, greasing.....199

Service and Maintenance Introduction.....201

Steering cylinder pins, greasing.....202

Swivel joint (horizontal and vertical) pins, greasing.....203

Tyres, checking air pressure.....206

Valves, adjusting_{10-40-26}.....208

Valves, adjusting_{10-40-53}.....213

Vertical swivel pin torque, checking.....221

Water separator, replacing.....224

Wheel nuts torque, checking.....226

19 - GENERAL.....227

A few simple safety rules.....228

Before operating.....232

Before service, read.....236

Charging batteries.....240

Check list after fire or heat exposure.....244

Cleanliness.....245

Decontamination.....249

Electrical system.....253

Environment.....257

Environmental handling for the future.....262

Health hazards with paint, plastics and rubber.....265

Safety concerns everybody!.....269

Safety when handling oil and fuel.....273

Safety when handling the machine.....276

Safety when lifting and supporting complete machine.....280

Safety when working with batteries.....282

Service position.....285

Some simple rules regarding tyre handling.....287

2 - ENGINE WITH MOUNTING AND EQUIPMENT.....289

20 - GENERAL.....290

Component locations_{10-22-47}.....291

Component locations_{10-23-15}.....294

E-ECU MID 128 non-programmed, replacing.....297

E-ECU MID 128 pre-programmed, replacing.....299

Engine belt, installing.....301

Engine belt, removing.....302

Engine, description_{10-25-00}.....303

Engine, description_{10-25-27}.....307

Engine, software specifications.....311

VCADS Pro, Operations.....313

21 - ENGINE.....315

Crankcase ventilation, description.....316

Cylinder compression, testing.....317

Engine rotation speed sensor (camshaft), replacing.....319

Engine rotation speed sensor (crank shaft), replacing_{10-18-25}.....321

Engine rotation speed sensor (crank shaft), replacing_{10-18-53}.....325

Engine, specifications_{10-19-31}.....328

Engine, specifications_{10-19-56}.....329

Engine, tightening torques_{10-16-47}.....330

Engine, tightening torques_{10-17-11}.....332

Oil sump, tightening torque.....334

Valves, adjusting_{10-14-20}.....337

Valves, adjusting_{10-14-52}.....342

22 - LUBRICATING SYSTEM.....350

Lubrication oil pressure, checking with pressure gauge.....351

Lubrication system, component locations.....354

Lubrication system, description.....357

Lubrication system, specifications_{10-11-34}.....361

Lubrication system, specifications_{10-12-02}.....363

Lubrication system, tightening torques.....365

23 - FUEL SYSTEM.....366

Carbon dioxide in fuel system, checking.....367

Feed pump pressure, checking.....369

Fuel level sender, replacing .....371

Fuel pump, replacing.....373

Fuel rail pressure sensor, replacing.....375

Fuel system, bleeding.....377

Fuel system, component location.....379

Fuel system, description_{10-08-34}.....381

Fuel system, description_{10-09-02}.....387

Fuel system, specifications.....393

Fuel system, tightening torques_{10-06-36}.....394

Fuel system, tightening torques_{10-07-00}.....395

Fuel system, tightening torques_{10-07-28}.....396

Fuel, specifications.....402

High pressure fuel system pressure, relieving.....403

Injectors, replacing.....405

Pressure relief valve (PRV), replacing.....420

25 - INLET & EXHAUST SYSTEM.....423

ACM (Aftertreatment control module) non-programmed, replacing.....425

ACM (Aftertreatment control module) pre-programmed, replacing.....427

Air pump safety valve, replacing.....429

Air pump, replacing_{09-42-01}.....431

Air pump, replacing_{09-42-29}.....437

Burner function, checking.....443

Burner, replacing.....449

DOC (Diesel oxidation catalyst), replacing_{09-38-24}.....459

DOC (Diesel oxidation catalyst), replacing_{09-38-52}.....467

DPF (Diesel particulate filter) inlet temperature sensor, replacing_{09-39-34}.....475

DPF (Diesel particulate filter) inlet temperature sensor, replacing_{09-40-02}.....477

DPF (Diesel particulate filter) outlet temperature sensor, replacing_{09-37-11}.....479

DPF (Diesel particulate filter) outlet temperature sensor, replacing_{09-37-38}.....483

Diesel particulate filter, check and clean_{09-51-22}.....487

Diesel particulate filter, check and clean_{09-51-51}.....494

Exhaust Aftertreatment System, component location_{09-52-33}.....501

Exhaust Aftertreatment System, component location_{09-53-01}.....504

Exhaust Aftertreatment System, description_{09-54-50}.....506

Exhaust Aftertreatment System, description_{09-55-22}.....518

Exhaust aftertreatment system, specifications.....530

Exhaust pipe flexible tube, replacing_{09-56-09}.....533

Exhaust pipe flexible tube, replacing_{09-56-37}.....536

Fuel metering unit A, replacing_{09-48-30}.....539

Fuel metering unit A, replacing_{09-48-57}.....544

Fuel metering unit B, replacing_{09-47-19}.....551

Fuel metering unit B, replacing_{09-47-48}.....564

Glow plug, replacing.....575

Inlet and exhaust system, component location_{09-58-02}.....577

Inlet and exhaust system, component location_{09-58-29}.....580

Inlet and exhaust system, description.....582

Inlet and exhaust system, specification.....586

Inlet and exhaust system, tightening torques.....587

Regeneration process, description.....589

Spark plug cable, replacing_{09-43-19}.....592

Spark plug cable, replacing_{09-43-47}.....594

Spark plug control unit, replacing_{09-50-13}.....596

Spark plug control unit, replacing_{09-50-40}.....599

Spark plug, inspecting.....601

Spark plug, replacing.....603

Turbocharger, description.....605

Turbocharger, replacing.....607

Wastegate, checking.....614

26 - COOLING SYSTEM.....616

Coolant pump, replacing.....617

Cooling fan motor, specifications.....620

Cooling fan, description.....621

Cooling system pressure, checking.....626

Cooling system, component location.....628

Cooling system, description_{09-34-08}.....631

Cooling system, description_{09-34-36}.....633

Cooling system, tightening torques_{09-32-07}.....635

Cooling system, tightening torques_{09-32-31}.....636

Fan pump, installing.....637

Fan pump, removing.....640

Fan pump, specifications.....642

Thermostat, replacing_{09-29-21}.....643

Thermostat, replacing_{09-29-49}.....648

Thermostat, specifications.....652

27 - ENGINE CONTROL.....653

Engine speed control switch, description.....654

29 - MISCELLANEOUS.....655

EGR actuator, replacing_{09-19-24}.....656

EGR actuator, replacing_{09-19-56}.....660

EGR cooler, replacing_{09-21-48}.....671

EGR cooler, replacing_{09-22-17}.....682

EGR reed valve, replacing.....695

EGR system function, checking.....697

EGR system, tightening torques.....701

EGR valve, replacing_{09-20-39}.....702

EGR valve, replacing_{09-21-06}.....706

EGR venturi tube, replacing.....708

Exhaust Gas Recirculation (EGR), description_{09-25-03}.....711

Exhaust Gas Recirculation (EGR), description_{09-25-31}.....716

Exhaust gas recirculation (EGR), component location_{09-23-54}.....721

Exhaust gas recirculation (EGR), component location_{09-24-21}.....723

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....725

30 - GENERAL.....726

Adapter cable 999 0014.....729

Adapter cable 999 0020.....730

Adapter cable 999 0216.....732

Adapter cable 999 3893.....733

CU2501, description and measuring.....734

CU2503, description and measuring.....736

Collection of basic data.....738

Communication with data buses.....740

Component fault diagnosis, description.....742

Conditions when checking.....745

Data links, fault tracing with Oscilloscope.....747

Electrical system, description.....757

Electrical system, specifications.....760

Electronic control system, description.....761

Extension cable 999 0062.....762

FX1007, description and measuring.....763

FX1031, description and measuring.....766

General fault diagnosis information.....769

Lead and connector checks.....770

MA2301-MA2304, description and measuring.....774

MA2301-MA2306, description and measuring.....776

MA2508, description and measuring.....778

MA2509, description and measuring.....780

MA2510, description and measuring.....782

MA2512, description and measuring.....787

MA4202, description and measuring_{08-53-59}.....789

MA4202, description and measuring_{08-54-26}.....791

MA4212, description and measuring.....793

MA4228, description and measuring.....795