Volvo Asphalt Compactors DD110B Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Asphalt Compactors DD110B Volvo, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Asphalt Compactors DD110B workshop service repair manual includes:
* 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 DD110B Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,160 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
MAIN SECTIONS
000 - Foreword....2
000 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torque; specifications_{07-52-27}....5
Tightening torque; specifications_{07-52-07}....7
Conversion tables....9
Thread locking compound; application_specifications....17
Critical mounting torques....19
Coolant; specifications....20
Hydraulic connections; tightening torques....21
07 - STANDARD TIME....24
Operation numbers for additional work....25
08 - TOOL....27
E-7019....28
88830095 Lifting tool user instructions....30
88830142 Adapter user instructions....35
88830352 Adapter user instructions....39
001 - STANDARD PARTS; SERVICE....43
16 - LUBRICANT; FUEL; OTHER FLUID....44
Fuel; lubricant and filling capacities....45
Recommended lubricants....46
17 - SERVICE....49
Engine; cleaning....52
Service and Maintenance Introduction....53
Maintenance service; daily....54
Maintenance service; every 50 hours....56
Maintenance service; every 500 hours....58
Maintenance service; every 1000 hours....60
Maintenance service; every 2000 hours....62
Maintenance service; every 3000 hours....63
Maintenance service; every 4500 hours....64
Maintenance service; every 6000 hours....65
Parking brake function; checking ....66
Emergency stop switch; checking....68
Winterization Procedure....69
Engine air cleaner primary filter; cleaning....71
Engine air cleaner primary filter; replacing....74
Engine air cleaner secondary filter; replacing....77
Engine air cleaner system integrity; checking....80
Fuel_water separator; draining....81
Water tank filter; checking....83
Water tank filter; cleaning....85
Spray bar; checking....87
Spray bar; cleaning....88
Engine oil level; checking....90
Coolant level; checking....92
Cooling system integrity; checking....94
Radiator and coolers; cleaning....95
Pump drive box oil level; checking....96
Lamp (indicator light); checking....98
Drum eccentric oil level; checking....101
Drum carrier oil level; checking....103
Hydraulic oil level; checking....105
Battery system integrity; checking....106
Drum carrier breather; cleaning....108
Water separator; replacing....110
Fuel system; bleeding ....112
Fuel filter; replacing....114
Fuel tank breather filter; replacing....116
Engine oil; draining....118
Engine oil; filling....120
Engine oil filter; replacing....122
Operator console rotation bearing; greasing....124
Steering cylinder pins; greasing....125
Swivel joint (horizontal and vertical) pins; greasing....127
Pump drive breather; cleaning....129
Hydraulic oil filters; replacing....131
Drum eccentric oil; draining....133
Drum eccentric oil; filling....135
Drum carrier oil; draining....137
Drum carrier oil; filling....139
Belt condition; checking....141
Water tank; draining....143
Water tank; filling....145
Water tank; cleaning....146
Vertical swivel pin torque; checking....147
Horizontal swivel pin torque; checking....149
Hydraulic oil tank breather filter; replacing....151
Hydraulic oil tank; draining....153
Hydraulic oil tank; filling....155
Hydraulic oil tank; cleaning....157
Hydraulic oil suction strainers; cleaning....160
Pump drive box oil; draining....163
Pump drive box oil; filling....166
Coolant mixture; checking....167
Valves; adjusting ....169
Spark plug; replacing ....176
DPF (Diesel particulate filter); checking and cleaning ....178
Coolant; draining....184
Coolant; filling....187
19 - GENERAL....189
Safety concerns everybody!....190
Service position....192
Safety when handling the machine....194
A few simple safety rules....197
Before operating....201
Before service; read....205
General....209
Cleanliness....214
Electrical system....218
Checklist after a fire or heat exposure....222
Health hazards with paint; plastics and rubber....225
Safety when handling oil and fuel....229
Safety when working with batteries....232
Charging batteries....235
Environment....239
Environmental handling for the future....244
Decontamination....247
Safety when lifting and supporting complete machine....251
002 - ENGINE WITH MOUNTING AND EQUIPMENT....253
026 - COOLING SYSTEM....254
Cooling system; description....255
Cooling system; component location....257
Cooling system; tightening torques....259
Cooling system pressure; checking....260
Coolant pump; replacing....262
Thermostat; replacing....272
Cooling fan; description....278
027 - ENGINE CONTROL....281
Engine speed control switch; description....282
029 - MISCELLANEOUS....283
Engine speed control switch; description....284
Exhaust Gas Recirculation (EGR); description....285
Exhaust gas recirculation (EGR); component location....290
EGR system; tightening torques....292
EGR reed valve; replacing....293
EGR cooler; replacing....295
EGR valve; replacing....305
EGR actuator; replacing....309
EGR system function; checking....313
20 - GENERAL....316
Engine; description....317
Engine; software specifications....321
Tech Tool; operations_{07-04-06}....322
VCADS Pro; Operations_{07-03-46}....324
Engine; volume....326
Component locations....327
E-ECU MID 128 pre-programmed; replacing....330
E-ECU MID 128 non-programmed; replacing....332
21 - ENGINE....334
Engine; specifications....335
Engine rotation speed sensor (crank shaft); replacing....336
Engine rotation speed sensor (camshaft); replacing....339
Engine; tightening torques....341
Cylinder compression; testing....343
Crankcase ventilation; description....345
Crankcase ventilation separator; replacing....346
Valves; adjusting....349
22 - LUBRICATING SYSTEM....356
Lubrication system; description....357
Lubrication system; specifications....361
Lubrication system; tightening torques....363
Lubrication system; component locations....364
Lubrication oil pressure; checking with pressure gauge....366
23 - FUEL SYSTEM....369
Fuel system; description....370
Fuel system; specifications....376
Fuel system; tightening torques....377
Carbon dioxide in fuel system; checking....378
Fuel system; component location....380
Fuel; specifications....382
Feed pump pressure; checking....383
Fuel pump; replacing....385
Fuel system; bleeding....394
Injectors; replacing....396
Fuel rail pressure sensor; replacing....410
Pressure relief valve (PRV); replacing....412
High pressure fuel system pressure; relieving....415
25 - INLET & EXHAUST SYSTEM....417
Inlet and exhaust system; description....418
Inlet and exhaust system; component location....422
Inlet and exhaust system; tightening torques....426
Exhaust pipe flexible tube; replacing....428
Exhaust Aftertreatment System; description....431
Exhaust Aftertreatment System; component location....443
Regeneration process; description....445
Exhaust aftertreatment system; specifications....448
DPF (Diesel particulate filter); checking and cleaning....451
DPF (Diesel particulate filter) inlet temperature sensor; replacing....457
Spark plug control unit; replacing....462
Glow plug; replacing....465
Fuel metering unit A; replacing....467
Fuel metering unit B; replacing....471
Air pump safety valve; replacing....482
DPF (Diesel particulate filter) outlet temperature sensor; replacing....484
ACM (Aftertreatment control module) non-programmed; replacing....489
ACM (Aftertreatment control module) pre-programmed; replacing....491
Spark plug; inspecting....493
Spark plug; replacing....495
Spark plug cable; replacing....497
Air pump; replacing....500
Burner function; checking....503
Burner; replacing....509
DPF (Diesel particulate filter) bracket; replacing....517
DOC (Diesel oxidation catalyst); replacing....522
Turbocharger; description....528
Turbocharger; replacing....530
Wastegate; checking....535
26 - COOLING SYSTEM....537
Cooling system; description....538
Cooling system; component location....540
Cooling system; tightening torques....542
Cooling system pressure; checking....543
Coolant pump; replacing....545
Thermostat; replacing....555
Cooling fan; description....561
27 - ENGINE CONTROL....564
Engine speed control switch; description....565
29 - MISCELLANEOUS....566
Engine speed control switch; description....567
Exhaust Gas Recirculation (EGR); description....568
Exhaust gas recirculation (EGR); component location....573
EGR system; tightening torques....575
EGR reed valve; replacing....576
EGR cooler; replacing....578
EGR valve; replacing....588
EGR actuator; replacing....592
EGR system function; checking....596
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....599
30 - GENERAL....600
Software; description....604
Electronic control system; description....605
Software versions and ECUs_part number; general....606
Software versions and ECUs_part number; checking....607
Electrical system; specifications_{06-20-58}....608
Electrical system; specifications_{06-20-39}....609
Tech Tool; description....610
Tech Tool; 17034-3 - Vehicle information; test....612
General fault diagnosis information....613
Troubleshooting strategy....614
Collection of basic data....616
Error code information; general....618
SAE error codes; translation to error messages; general....620
Conditions when checking....623
Lead and connector checks....625
Troubleshooting tools....629
Special tools for troubleshooting....630
Tech Tool....631
AL3201; description and measuring....635
CU2501; description and measuring....637
CU2503; description and measuring....638
DI9106; description and measuring....639
DI9108; description and measuring....641
DI9109; description and measuring....642
FX1007; description and measuring....643
FX1031; description and measuring....645
HE2501; description and measuring....647
MA2301-MA2304; description and measuring....648
MA2508; description and measuring....650
MA2509; description and measuring....651
MA2510; description and measuring....652
MA2512; description and measuring....654
MA4211; description and measuring....656
MA4212; description and measuring_{06-04-51}....658
MA4212; description and measuring_{06-04-28}....660
MO2502; description and measuring....662
MO2505; description and measuring....664
MO3301; description and measuring....666
MO9404; description and measuring....667
MO9405; description and measuring....668
MO9406; description and measuring....670
MO9407; description and measuring....671
MO9408; description and measuring....673
PWM2303; description and measuring....674
PWM2601; description and measuring....675
PWM4202; description and measuring_{05-57-38}....677
PWM4202; description and measuring_{05-57-12}....679
PWM4219; description and measuring_{05-56-39}....681
PWM4219; description and measuring_{05-56-16}....683
PWM9426; description and measuring_{05-55-40}....685
PWM9426; description and measuring_{05-55-18}....687
PWM9427; description and measuring_{05-54-45}....689
PWM9427; description and measuring_{05-54-23}....691
PWM9428; description and measuring_{05-53-50}....693
PWM9428; description and measuring_{05-53-28}....695
PWM9429; description and measuring_{05-52-49}....697
PWM9429; description and measuring_{05-52-27}....699
RE2501; description and measuring....701
RE3101; description and measuring....703
RE3102; description and measuring....705
RE3301; description and measuring....707
RE3303; description and measuring....709
RE3304; description and measuring....711
RE3305; description and measuring....713
SA3601; description and measuring....715
SA3602; description and measuring....717
SA4201; description and measuring....718
SE2203; description and measuring....719
SE2301; description and measuring....720
SE2302; description and measuring....721
SE2303; description and measuring....722
SE2309; description and measuring....724
SE2501; description and measuring....727
SE2512; description and measuring....728
SE2519; description and measuring....730
SE2520; description and measuring....731
SE2521; description and measuring....732
SE2522; description and measuring....734
SE2523; description and measuring....736
SE2524; description and measuring....737
SE2525; description and measuring....738
SE2526; description and measuring....740
SE2530; description and measuring....741
SE2603; description and measuring....742
SE2606; description and measuring....743
SE2701; description and measuring....745
SE2704; description and measuring....746
SE5501; description and measuring....747
SE8501; description and measuring....748
SE9105; description and measuring_{05-34-28}....749
SE9105; description and measuring_{05-34-06}....751
SE9107; description and measuring....753
SE9428; description and measuring....754
SE9429; description and measuring....755
SE9430; description and measuring....756
SE9433; description and measuring....757
SE9535; description and measuring....758
SE9536; description and measuring....759
Multimeter 8889 0074....760
Test pins 999 0008....761
Adapter cable 999 0014....762
Extension cable 999 0062....763
Multi-pin breaker box 999 8699....764
Template 8889 0019....765
Adapter cable 999 0216....766
Component fault diagnosis; description....767
Test methods; description....770
31 - BATTERY....774
Battery; specifications....775
33 - STARTING SYSTEM....776
Starter motor; tightening torques....777
36 - OTHER ELECTRICAL EQUIPMENT....780
Instrument control unit I-ECU; description....781
Vehicle control unit V-ECU; description....784
Engine control unit E-ECU; description....785
I-ECU MID 140 non-programmed; replacing....786
I-ECU MID 140 pre-programmed; replacing....788
V-ECU MID 187 pre-programmed; replacing....790
V-ECU MID 187 non-programmed; replacing....792
37 - CABLE; FUSE; RELAY....795
Electrical symbols and designations....797
Explanation of wiring diagrams....801
Component list; fuses....804
Component list; relays....807
Electrical component list....810
Wiring diagram index....814
Wiring diagram 1_{05-16-04}....815
Wiring diagram 1_{05-15-42}....818
Wiring diagram 2_{05-15-09}....820
Wiring diagram 2_{05-14-46}....823
Wiring diagram 3_{05-14-07}....825
Wiring diagram 3_{05-13-45}....828
Wiring diagram 4_{05-13-11}....831
Wiring diagram 4_{05-12-48}....834
Wiring diagram 5_{05-12-14}....837
Wiring diagram 5_{05-11-52}....840
Wiring diagram 6_{05-11-19}....842
Wiring diagram 6_{05-10-57}....845
Wiring diagram 7_{05-10-17}....847
Wiring diagram 7_{05-09-55}....849
Wiring diagram 8_{05-09-21}....852
Wiring diagram 8_{05-08-59}....855
Wiring diagram 9_{05-08-20}....858
Wiring diagram 9_{05-07-58}....861
Wiring diagram 10_{05-07-18}....864
Wiring diagram 10_{05-06-56}....867
Wiring diagram 11_{05-06-22}....870
Wiring diagram 11_{05-06-00}....873
Wiring diagram 12_{05-05-26}....876
Wiring diagram 12_{05-05-04}....879
Wiring diagram 13_{05-04-25}....881
Wiring diagram 13_{05-04-03}....884
Wiring diagram 14_{05-03-29}....887
Wiring diagram 14_{05-03-07}....890
Wiring diagram 15_{05-02-33}....893
Wiring diagram 15_{05-02-11}....896
Wiring diagram 16_{05-01-26}....898
Wiring diagram 16_{05-01-04}....901
Wiring diagram 17_{05-00-30}....903
Wiring diagram 17_{05-00-08}....904
Wiring diagram 18_{04-59-35}....905
Wiring diagram 18_{04-59-13}....908
Wiring diagram 19....910
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....913
Compact assist; functional description....914
Volvo Co-Pilot; description....918
Volvo Co-Pilot; component location....920
Volvo Co-Pilot; replacing....921
Volvo Co-Pilot SIM card; installing....923
Volvo Co-Pilot Android software; updating online (OtA)....926
Volvo Co-Pilot Android software; updating offline (USB)....928
Volvo Co-Pilot Android software offline (USB) update; checking....931
004 - POWER TRANSMISSION....933
42 - TRANSMISSION; HYDRAULIC CONTROL....934
Propulsion control lever; replacing....935
44 - HYDROSTATIC DRIVE....939
Hydrostatic drive system; description_{04-52-11}....940
Hydrostatic drive system; description_{04-51-49}....944
Propulsion pump; description_{04-51-15}....948
Propulsion pump; description_{04-50-53}....950
Propulsion pump; specifications....953
Drum drive motor; description_{04-49-58}....954
Drum drive motor; description_{04-49-40}....956
Drum drive motor; specifications....959
Brake_shunt valve function; description....960
Thermal bypass valve; description....962
Thermal bypass valve; specifications....964
Loop flushing valve; description....965
Propel; calibrating....967
Propulsion pump charge pressure; checking....969
Propulsion pump system pressure; checking....972
Propulsion pump; removing....975
Propulsion pump; installing....980
005 - BRAKE....986
55 - PARKING BRAKE....987
Parking brake; function description....988
Drum brake; specifications....992
Parking brake function; checking....993
006 - STEERING....995
60 - GENERAL....996
Steering pump; description....997
Steering system; description....999
Steering valve; description....1003
Steering pump; specifications....1005
Steering valve; specifications....1006
64 - STEERING....1007
Steering cylinder; replacing....1008
Steering pump; removing....1011
Steering pump; installing....1016
Steering valve; replacing....1022
Steering pressure; checking....1026
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1029
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1030
Vibration motor; specifications....1032
Vibration pump; specifications....1033
Drum vibration; specifications....1034
Vibration motor; description....1035
Vibration pump; description_{04-38-34}....1037
Vibration pump; description_{04-38-12}....1040
Vibration system; description_{04-37-38}....1043
Vibration system; description_{04-37-20}....1047
Vibration system; description_{04-37-01}....1051
Carrier; removing....1055
Carrier; installing....1060
Drum; removing....1065
Drum; installing....1071
Eccentric weight; removing....1077
Eccentric weight; installing....1083
Drum drive motor; replacing....1090
Vibration motor; removing....1093
Vibration motor; installing....1095
Vibration pump; removing_{04-32-27}....1098
Vibration pump; removing_{04-32-05}....1103
Vibration pump; installing_{04-31-32}....1106
Vibration pump; installing_{04-31-06}....1111
Eccentric weight; overhauling....1115
Eccentric weight bearings; replacing....1119
Carrier bearings; replacing....1126
Drum drive assembly; removing....1129
Drum drive assembly; installing....1132
Vibration pump charge pressure; checking....1134
Vibration pump charge pressure relief valve; adjusting....1137
Vibration system pressure; checking....1139
Vibration pump charge pressure relief valve; replacing....1144
Vibration pump SCR (system check_relief) valve; replacing....1146
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1148
90 - GENERAL....1149
Hydraulic diagram 1_{04-26-17}....1150
Explanations to hydraulic diagram_{04-25-55}....1151
Hydraulic diagram 2_{04-25-25}....1154
Explanations to hydraulic diagram_{04-25-03}....1155
98 - FUNCTION FOR ROAD CONSTRUCTION....1158
Water tank; removing....1159
Water tank; installing....1163
Volvo Asphalt Compactors DD110B Repair Service Manual
