Volvo DD25B Asphalt Compactor Workshop Service Repair Manual PDF - MNVLVCONDD25B.zip

A full workshop manual featuring complete wiring schematics for the Volvo DD25B Asphalt Compactor, packed with everything needed to maintain, troubleshoot, fix, and service the machine the way a trained technician would.

The Volvo Construction Equipment DD25B asphalt compactor service and repair manual 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.

Volvo Asphalt Compactors DD25B 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 pagesL 547

File Format: PDF (Windows & Mac & Linux)

Language: English

TABLE OF CONTENTS

0 - Foreword.....2

0 - GENERAL.....3

03 - SPECIFICATIONS.....4

Component locations .....5

Conversion tables.....7

Thread locking compound, application_specifications.....15

Tightening torque, specifications_{11-36-03}.....17

Tightening torque, specifications_{11-36-14}.....19

07 - STANDARD TIME.....21

Operation numbers for additional work.....22

08 - TOOL.....24

E-7018.....25

1 - STANDARD PARTS, SERVICE.....26

16 - LUBRICANT; FUEL; OTHER FLUID.....27

Alternative fuels.....28

Coolant.....31

Fuel, lubricant and filling capacities.....33

Recommended lubricants.....34

17 - SERVICE.....36

Air inlet hose, checking.....38

Arrival Inspection, according to Inspection Programme.....39

Battery terminals, cleaning.....40

Bolted joints, checking.....41

Coolant level, checking.....42

Coolant's freezing point, check.....44

Coolant, draining.....46

Coolant, filling.....48

Delivery Inspection, according to Inspection Programme.....50

Drum shock mounts, checking.....51

Edge compactor, greasing.....52

Emergency stop switch, checking.....53

Engine air cleaner contamination indicator, checking.....54

Engine air cleaner, replacing.....55

Engine belt condition, checking.....57

Engine belt tension, adjusting.....58

Engine belt tension, checking.....59

Engine coolant hoses, checking.....61

Engine mounts, checking.....63

Engine oil filter, replacing.....64

Engine oil level, checking.....66

Engine oil, drain.....68

Engine oil, filling.....70

Exhaust manifold, checking.....72

Fuel fine filter, changing.....74

Fuel injector, testing-.....76

Fuel lines, checking.....77

Fuel prefilter, changing.....78

Fuel prefilter, checking.....80

Hydraulic oil filter contamination indicator, checking.....81

Hydraulic oil filter, changing.....83

Hydraulic oil level, checking.....85

Hydraulic oil, draining.....87

Hydraulic oil, filling.....89

Hydraulic tank ventilation filter, changing.....91

Injection pump, checking.....93

Leakage, checking.....99

Maintenance of Stored Machines, according to Inspection Programme.....100

Maintenance service, every 010 hours.....101

Maintenance service, every 050 hours.....103

Maintenance service, every 1000 hours.....104

Maintenance service, every 2000 hours.....106

Maintenance service, every 3000 hours.....108

Maintenance service, every 500 hours.....109

Maintenance service, every 6000 hours.....111

Parking brake, checking.....112

Propulsion control lever, greasing.....114

Radiator, cleaning.....116

Seat belt, checking.....118

Service.....120

Spray bar, checking.....123

Steering joint, greasing.....125

Valves, adjusting .....127

Water tank, cleaning.....131

19 - GENERAL.....133

CE-marking, EMC-directive.....134

Checklist after a fire or heat exposure.....136

Cleanliness.....138

Environmentally safe handling.....142

Safety concerns everybody!.....144

Safety when handling oils and fuel.....148

Safety when working on hydraulic systems.....150

Service position.....152

Working on the electrical system of the machine.....154

2 - ENGINE WITH MOUNTING AND EQUIPMENT.....156

20 - GENERAL.....157

Component location.....158

Engine belts, replacing.....161

Engine, description.....163

21 - ENGINE.....166

Engine mounts, replacing.....167

Engine, specifications.....169

Engine, tightening torques.....171

Valves, adjusting.....172

22 - LUBRICATING SYSTEM.....176

Lubricating system, description.....177

Lubrication oil pressure, checking with pressure gauge.....180

Lubrication system, component locations.....183

Lubrication system, specifications.....185

Lubrication system, tightening torques.....186

23 - FUEL SYSTEM.....187

Fuel injector, testing.....188

Fuel pump, installing.....189

Fuel pump, removing.....191

Fuel system, bleeding.....193

Fuel system, component location.....194

Fuel system, description.....196

Fuel system, specifications.....199

Fuel system, tightening torques.....200

High pressure fuel pump, checking.....201

High pressure fuel pump, replacing.....207

Injectors, replacing.....213

25 - INLET & EXHAUST SYSTEM.....219

Glow plug, replacing.....220

26 - COOLING SYSTEM.....222

Coolant pump, replacing.....223

Cooling system, component location.....225

Cooling system, description.....227

Cooling system, specification.....229

Radiator, installing.....230

Radiator, removing.....233

Thermostat, replacing.....236

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....238

30 - GENERAL.....239

Electrical system, description.....240

Electrical system, instructions .....241

Electrical system, instructions.....242

Instruments and controls, overview_{011-02-42}.....243

Instruments and controls, overview_{011-02-54}.....247

Troubleshooting.....250

31 - BATTERY.....253

Battery, charging.....254

Battery, description.....256

32 - ALTERNATOR; CHARGE REGULATOR.....257

Alternator, installing.....258

Alternator, removing.....260

35 - LIGHTING.....262

Light bulb, replacing.....263

36 - OTHER ELECTRICAL EQUIPMENT.....265

Reverse alarm, replacing.....266

37 - CABLE; FUSE; RELAY.....268

Battery disconnector switch, description.....270

Battery disconnector, installing.....272

Battery disconnector, removing.....274

Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{010-58-33}.....276

Component list Alternator, batteries, capacitors, electronic units, voltage outlet_{010-58-43}.....277

Component list Fuses.....278

Component list Lights.....279

Component list Relays_{010-57-20}.....280

Component list Relays_{010-57-31}.....281

Component list Solenoid valves.....282

Component list Switches.....284

Component list, Sounders_{010-56-22}.....285

Component list, Sounders_{010-56-32}.....286

Component list, motors.....287

Component list, sensors.....288

Component locations.....289

Control and warning instrument_{010-47-37}.....291

Control and warning instrument_{010-47-50}.....294

Fuses.....298

Overview.....300

Relays.....301

Wiring diagram 001_{10-55-26}.....303

Wiring diagram 001_{10-55-39}.....306

Wiring diagram 002_{10-54-42}.....309

Wiring diagram 002_{10-54-55}.....312

Wiring diagram 003_{10-54-12}.....315

Wiring diagram 003_{10-54-24}.....318

Wiring diagram 004_{10-53-39}.....321

Wiring diagram 004_{10-53-52}.....324

Wiring diagram 005_{10-53-09}.....327

Wiring diagram 005_{10-53-21}.....330

Wiring diagram 006_{10-52-37}.....333

Wiring diagram 006_{10-52-50}.....336

Wiring diagram 007_{10-52-06}.....339

Wiring diagram 007_{10-52-18}.....342

Wiring diagram 008_{10-51-34}.....345

Wiring diagram 008_{10-51-47}.....348

Wiring diagram 009_{10-51-02}.....351

Wiring diagram 009_{10-51-15}.....354

Wiring diagram 010_{10-50-31}.....357

Wiring diagram 010_{10-50-44}.....360

Wiring diagram 011_{10-50-02}.....363

Wiring diagram 011_{10-50-14}.....366

Working functions_{010-47-10}.....369

Working functions_{010-47-24}.....372

4 - POWER TRANSMISSION.....375

40 - GENERAL.....376

Power transmission, specifications.....377

44 - HYDROSTATIC DRIVE.....378

Drive motor, installing.....379

Drive motor, removing.....381

Travel lever throttle cable, adjusting.....383

Travel lever throttle cable, installing.....385

Travel lever throttle cable, removing.....387

5 - BRAKE.....389

50 - GENERAL.....390

Brake system, description.....391

Brake, specifications.....392

55 - PARKING BRAKE.....393

Parking brake, activate manually.....394

Parking brake, deactivate manually.....395

6 - STEERING.....397

60 - GENERAL.....398

Steering unit, specification.....399

64 - STEERING.....400

Steering cylinder, installing.....401

Steering cylinder, removing.....404

Steering pump, installing.....407

Steering pump, removing.....409

7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....411

74 - FRAME LINK.....412

Articulation hinge, assembling.....413

Articulation hinge, component location.....417

Articulation hinge, disassembling.....420

77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....424

Drum drive, installing.....425

Drum rubber cushions, replacing_{010-35-52}.....427

Drum rubber cushions, replacing_{010-36-04}.....429

Drum, installing.....433

Drum, removing.....435

Eccentric shaft bearings, installing_{010-36-22}.....438

Eccentric shaft bearings, installing_{010-36-33}.....440

Eccentric shaft bearings, removing_{010-36-51}.....442

Eccentric shaft bearings, removing_{010-37-03}.....444

Eccentric shaft, installing.....446

Eccentric shaft, removing.....449

Offset drum, adjusting.....453

Scraper set, installing.....456

Scraper set, removing.....458

Scraper strip, replacing.....460

Travel bearings, installing.....462

Travel bearings, removing.....466

Vibration motor, installing.....470

Vibration motor, removing.....472

Vibration pump, installing.....474

Vibration pump, removing.....476

8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....478

82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....479

Engine hood, installing.....480

Engine hood, removing.....482

85 - CAB INTERIOR; UPHOLSTERY.....484

Operator's seat, installing.....485

Operator's seat, removing.....489

86 - PROTECTIVE EQUIPMENT.....491

ROPS (Roll Over Protection), installing.....492

ROPS (Roll Over Protection), removing.....494

88 - INTERIOR EQUIPMENT.....496

Seat safety belt, replacing.....497

9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....500

90 - GENERAL.....501

Hydraulic hoses, overview.....502

Hydraulic pressure, checking.....504

Hydraulic system component location.....510

Hydraulic system, description.....512

Hydraulic system, specification.....513

Oil and filtration.....514

91 - WORKING HYDRAULIC; SERVO HYDRAULICS.....515

Explanations to hydraulic diagram.....516

Hydraulic diagram 001_{10-30-44}.....519

Hydraulic diagram 001_{10-30-57}.....521

Hydraulic diagram 002_{10-30-14}.....523

Hydraulic diagram 002_{10-30-26}.....525

Hydraulic oil tank, component location.....527

Hydraulic oil tank, installing.....529

Hydraulic oil tank, removing.....531

98 - FUNCTION FOR ROAD CONSTRUCTION.....533

Vibration frequency, adjusting.....534

Vibration frequency, checking.....535

Vibration, specifications.....537

Water pump, description.....538

Water pump, installing.....539

Water pump, removing.....541

Water spray system, component location.....543