Asphalt Compactors DD110C Volvo Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Asphalt Compactors DD110C Volvo, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Asphalt Compactors DD110C Volvo 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.
PRODUCT DETAILS:
Total Pages: 1,203 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
Asphalt Compactors DD110C Volvo Service Repair Manual.pdf
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
03 - SPECIFICATIONS................4
Tightening torque; specifications................5
Thread locking compound; application_specifications................7
Hydraulic connections; tightening torques................9
07 - STANDARD TIME................16
Operation numbers for additional work................17
08 - TOOL................19
E-7019................20
88830095 Lifting tool user instructions................22
88830142 Adapter user instructions................27
88830352 Adapter user instructions................31
Infrared Thermometer................35
1 - STANDARD PARTS; SERVICE................37
16 - LUBRICANT; FUEL; OTHER FLUID................38
AdBlue®_DEF ................39
Fuel; lubricant and filling capacities................45
Recommended lubricants................46
17 - SERVICE................49
Tech Tool; operations ................51
Service and Maintenance Introduction................52
Maintenance service; first 50 hours................53
Maintenance service; every 10 hours................54
Maintenance service; every 50 hours................55
Maintenance service; every 500 hours................57
Maintenance service; every 1000 hours................59
Maintenance service; every 2000 hours................61
Maintenance service; every 3000 hours................63
Maintenance service; every 4000 hours................65
Maintenance service; every 6000 hours................67
Maintenance service; every 8000 hours................68
Service position ................69
Lubrication; every 500 hours................72
Engine belt condition; checking................75
Valves; adjusting ................77
Engine oil level; checking................81
Engine oil and filter; changing................82
Water separator; checking................85
Fuel filter; replacing................87
Water separator filter; replacing................89
Fuel tank breather filter; replacing................91
Diesel particulate filter; regenerating................93
Diesel particulate filter; checking and cleaning................94
AdBlue®_DEF pump unit filter; replacing................102
AdBlue®_DEF tank breather filter; replacing................105
Engine air cleaner system integrity; checking................107
Engine air cleaner primary filter; cleaning................109
Engine air cleaner primary filter; replacing................112
Engine air cleaner secondary filter; replacing................115
Coolant level; checking................118
Coolant; changing................119
Coolant freezing point; checking................122
Cooling system integrity; checking................125
Software update; checking................127
Battery system integrity; checking................131
Emergency stop switch; testing................133
Planetary drive oil level; checking................134
Planetary drive oil; changing................136
Pump drive box oil level; checking................138
Pump drive box oil; changing................139
Pump drive box breather; cleaning................141
Parking brake function; checking................142
Articulation pin torque; checking................144
Oscillation pin torque; checking................146
Drum eccentric oil level; checking................148
Drum eccentric oil; changing................150
Drum carrier oil level; checking................152
Drum carrier oil; changing................154
Drum carrier breather; cleaning................157
Hydraulic oil level; checking................159
Hydraulic oil; changing................160
Hydraulic oil filters; replacing................163
Hydraulic oil tank breather filter; replacing................165
Water tank; cleaning................166
Water pump filter; checking................168
Spray bar; checking................171
Starting with booster batteries................173
Towing a disabled machine................175
19 - GENERAL................179
Safety concerns everybody!................180
Service position................184
Safety when handling the machine................187
A few simple safety rules................191
Before operating................195
Before service; read................199
General................203
Cleanliness................208
Electrical system................212
Checklist after a fire or heat exposure................216
Health hazards with paint; plastics and rubber................219
Safety when handling oil and fuel................223
Safety when working with batteries................226
Charging batteries................229
Environment................233
Environmental handling for the future................238
Decontamination................241
Safety when lifting and supporting complete machine................245
2 - ENGINE WITH MOUNTING AND EQUIPMENT................247
20 - GENERAL................248
Engine; description................249
Tech Tool; operations-[0545]................255
Engine control module (ECM); replacing pre-programmed................257
Engine control module (ECM); replacing non-programmed................260
Engine belt; removing................263
Engine belt; installing................267
21 - ENGINE................271
Engine; removing................272
Engine; installing................283
Engine; specifications................294
Engine; tightening torques_{11-01-03}................296
Engine; tightening torques_{11-00-40}................298
Cylinder compression; testing................307
Valves; adjusting................310
Valve cover; removing................311
Valve cover; installing................315
22 - LUBRICATING SYSTEM................319
Lubrication system; description................320
Lubrication system; specifications................325
Lubrication system; component locations................327
Lubrication system; tightening torques................329
Lubrication oil pressure; checking with pressure gauge................332
23 - FUEL SYSTEM................335
Fuel system; description................336
Fuel system; specifications................344
Fuel system; tightening torques................346
Carbon dioxide in fuel system; checking................354
Fuel system; component location................360
Feed pump pressure; checking................362
Fuel pump; replacing................365
Fuel system; bleeding................368
Injectors; replacing................370
Fuel rail; replacing................376
Fuel rail pressure sensor; replacing................379
High pressure fuel pump; replacing................381
High pressure fuel pipes; replacing................384
Fuel control valve (FCV); replacing................386
Pressure relief valve (PRV); replacing................390
25 - INLET & EXHAUST SYSTEM................392
Inlet and exhaust system; description................394
Inlet and exhaust system; specification................400
Inlet and exhaust system; component location................401
Inlet and exhaust system; tightening torques_{10-42-25}................403
Inlet and exhaust system; tightening torques_{10-42-03}................405
Exhaust pipe flexible tube; replacing................411
Exhaust Aftertreatment System; description................413
Exhaust Aftertreatment System; component location................426
Regeneration process; description................428
AdBlue®_DEF dosing injector; replacing................435
AdBlue®_DEF mixing tube; replacing................438
AdBlue®_DEF tank; replacing................443
AdBlue®_DEF; draining................451
Coolant valve; replacing................453
SCR (Selective catalytic reduction) muffler; replacing................457
Exhaust aftertreatment system assembly; removing................460
Exhaust aftertreatment system assembly; installing................464
AdBlue®_DEF quality; checking................469
SCR (Selective catalytic reduction) dosing system; checking................472
AdBlue®_DEF pump unit diagnostics; description................474
DPF (Diesel particulate filter); checking and cleaning................478
ACM (Aftertreatment control module) non-programmed; replacing................479
ACM (Aftertreatment control module) pre-programmed; replacing................482
Inlet throttle; replacing................485
DOC (Diesel oxidation catalyst); replacing................488
AdBlue®_DEF pump unit; replacing................496
AdBlue®_DEF tank armature; replacing................500
AdBlue®_DEF tank armature; cleaning................508
AdBlue®_DEF tank armature suction filter; replacing................511
AdBlue®_DEF................513
Crystallization of AdBlue®_DEF; checking................519
AdBlue®_DEF pump unit; flushing................524
AdBlue®_DEF pump unit; inlet nipple; replacing................527
Regeneration log; checking................529
Turbocharger; replacing................541
Wastegate; checking................547
Air cleaner; removing................549
Air cleaner; installing................551
Preheating coil; replacing................553
26 - COOLING SYSTEM................558
Cooling system; description................559
Carbon dioxide in coolant system; checking................563
Cooling system; component location................569
Cooling system; tightening torques_{10-21-14}................571
Cooling system; tightening torques_{10-20-51}................575
Cooling package; removing................577
Cooling package; installing................595
Coolant pump; replacing................613
Thermostat; replacing................617
Cooling fan; description................620
29 - MISCELLANEOUS................622
Exhaust Gas Recirculation (EGR); description................623
Exhaust gas recirculation (EGR); component location................629
EGR system; tightening torques................631
EGR reed valve; replacing................633
EGR cooler; replacing................641
EGR actuator; replacing................652
EGR venturi tube; replacing................655
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................661
30 - GENERAL................662
Electrical system; tightening torques................666
Troubleshooting strategy................668
Collection of basic data................670
Conditions when checking................672
Tech Tool Service Tool................674
Tech Tool; operations................677
AL3201; description and measuring................678
BB1 Communication bus; description and measuring................680
BB2 Communication bus; description and measuring................683
CAN3; description and measuring................686
FX1007; description and measuring................689
FX1008; description and measuring................691
FX1074; description and measuring................693
FX1079; description and measuring................696
HE2501; description and measuring................698
HE2511; description and measuring................700
HE2512; description and measuring................702
HE2513; description and measuring................704
K15; description and measuring................706
MA2301-MA2304; description and measuring................708
MA2517; description and measuring................710
MA2519; description and measuring................711
MA4202; description and measuring................713
MA4212; description and measuring................715
MA4407; description and measuring................717
MO2503; description and measuring................719
MO2505; description and measuring................721
MO3301; description and measuring................724
MO9404; description and measuring................726
MO9405; description and measuring................728
MO9406; description and measuring................730
MO9407; description and measuring................732
Power supply; ACM (Aftertreatment Control Module); description and measuring................734
Power supply ECM; description and measuring................736
Power supply GPMECU 1; description and measuring................738
Power supply HMICU; description and measuring................740
Power supply W-ECU; description and measuring................742
PWM2303; description and measuring................744
PWM9150; description and measuring................746
PWM9426; description and measuring................748
PWM9427; description and measuring................750
PWM9428; description and measuring................752
PWM9429; description and measuring................754
RE01; description and measuring................756
RE05; description and measuring................758
RE07; description and measuring................760
RE08; description and measuring................762
RE09; description and measuring................764
RE2501; description and measuring................766
RE3103; description and measuring................768
RE3705; description and measuring................770
SA3601; description and measuring................773
SAE J1939-1 SubNet 1; description and measuring................775
SE2203; description and measuring................778
SE2301; description and measuring................780
SE2302; description and measuring................782
SE2303; description and measuring................783
SE2309; description and measuring................785
SE2507; description and measuring................786
SE2511; description and measuring................788
SE2513; description and measuring................789
SE2515; description and measuring................791
SE2516; description and measuring................793
SE2519; description and measuring................795
SE2521; description and measuring................797
SE2522; description and measuring................799
SE2530; description and measuring................801
SE2531; description and measuring................803
SE2533; description and measuring................805
SE2543; description and measuring................808
SE2544; description and measuring................810
SE2601; description and measuring................812
SE2603; description and measuring................813
SE2606; description and measuring................815
SE2701; description and measuring................817
SE2703; description and measuring................819
SE5501; description and measuring................821
SE8501; description and measuring................823
SE8502; description and measuring................824
SE8705; description and measuring................826
SE9105; description and measuring................828
SE9106; description and measuring................830
SE9426; description and measuring................831
SE9429; description and measuring................832
SE9430; description and measuring................833
SE9433; description and measuring................834
SE9536; description and measuring................836
SW5501; description and measuring................838
Multimeter 8889 0074................840
Test pins 999 0008................841
Adapter cable 999 0014................842
Adapter cable 999 0020................843
Extension cable 999 0062................844
Adapter cable 999 3893................845
Adapter cable 999 8534................846
Multi-pin breaker box 999 8699................847
Template 8889 0019................848
Adapter cable 999 0216................849
Component fault diagnosis; description................850
Test methods; description................853
31 - BATTERY................857
Batteries; replacing................858
32 - ALTERNATOR; CHARGE REGULATOR................861
Alternator; removing................862
Alternator; installing................865
33 - STARTING SYSTEM................867
Starting system; description................868
Starter motor; tightening torques................871
36 - OTHER ELECTRICAL EQUIPMENT................874
GPMECU; changing non-programmed ECU................875
GPMECU; changing pre-programmed ECU................877
HMICU non-programmed; replacing................879
HMICU pre-programmed; replacing................881
37 - CABLE; FUSE; RELAY................883
Electrical symbols and designations................885
Explanation of wiring diagrams................889
Component list; Diodes................892
Component list; fuses................893
Component list; Miscellaneous................896
Component list; motors................898
Component list; relays................899
Component list; sensors................901
Component list; Solenoid valves................903
ACM; I_O list................904
E-ECU; I_O list................906
GPM-ECU; I_O list................910
HMICU; I_O list................914
W-ECU; I_O list................916
Wiring diagram index................917
Wiring diagram 1................918
Wiring diagram 2................921
Wiring diagram 3................924
Wiring diagram 4................927
Wiring diagram 5................930
Wiring diagram 6................933
Wiring diagram 7................936
Wiring diagram 8................939
Wiring diagram 9................942
Wiring diagram 10................945
Wiring diagram 11................948
Wiring diagram 12................951
Wiring diagram 13................954
Wiring diagram 14................957
Wiring diagram 15................960
Wiring diagram 16................963
Wiring diagram 17................966
Wiring diagram 18................969
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................972
Mat temperature sensor; replacing................973
Compact assist; functional description................976
Volvo Co-Pilot; description................980
Volvo Co-Pilot; component location................982
Volvo Co-Pilot; replacing................983
Volvo Co-Pilot SIM card; installing................985
Volvo Co-Pilot Android software; updating online (OtA)................988
Volvo Co-Pilot Android software; updating offline (USB)................990
Volvo Co-Pilot Android software offline (USB) update; checking................993
Smart Receiver; replacing................995
GNSS Antenna; replacing................997
Inertial measurement unit (IMU); replacing................999
Display unit; troubleshooting................1002
4 - POWER TRANSMISSION................1005
42 - TRANSMISSION; HYDRAULIC CONTROL................1006
Propulsion control lever; replacing................1007
44 - HYDROSTATIC DRIVE................1010
Pump drive box; installing................1011
Pump drive box; removing................1013
Propulsion pump; installing................1015
Propulsion pump; removing................1021
Propulsion planetary; installing................1027
Propulsion planetary; removing................1030
Thermal bypass valve; specifications................1033
Thermal bypass valve; description................1034
Drum drive motor; specifications................1036
Propulsion system pressure; checking................1037
Propulsion pump; specifications................1041
Hydrostatic drive system; description................1042
Propulsion system; tightening torques................1045
5 - BRAKE................1048
55 - PARKING BRAKE................1049
Drum brake; specifications................1050
Parking brake; function description................1051
6 - STEERING................1054
60 - GENERAL................1055
Steering system; description................1056
Steering; tightening torques................1059
Steering pump; specifications................1061
Steering valve; specifications................1062
64 - STEERING................1063
Steering cylinder; replacing................1064
Steering pump; removing................1067
Steering pump; installing................1069
Steering valve; replacing................1071
Steering pressure; checking................1073
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................1075
71 - FRAME................1076
Frame; tightening torques................1077
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................1078
Vibration motor; specifications................1079
Vibration pump; specifications................1080
Drum vibration; specifications................1081
Vibration system; description................1082
Drum; tightening torques................1085
Carrier; removing................1088
Carrier; installing................1093
Drum; removing................1098
Drum; installing................1103
Eccentric weight; removing................1109
Eccentric weight; installing................1115
Drum drive motor; replacing................1122
Vibration motor; removing................1126
Vibration motor; installing................1128
Vibration pump; removing_{12-01-41}................1130
Vibration pump; removing_{12-01-19}................1134
Vibration pump; installing_{12-00-40}................1138
Vibration pump; installing_{12-00-18}................1142
Eccentric weight; overhauling................1146
Eccentric weight bearings; replacing................1150
Carrier bearings; replacing................1157
Drum drive assembly; removing................1160
Drum drive assembly; installing................1163
Vibration pump charge pressure relief valve; adjusting................1165
Vibration system pressure; checking................1167
Vibration pump charge pressure relief valve; replacing................1172
Vibration pump SCR (system check_relief) valve; replacing................1174
Vibration speed sensor; replacing................1176
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................1178
82 - ENGINE HOOD; MUDGUARD; FOOT STEP................1179
Engine hood; removing................1180
Engine hood; installing................1183
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................1186
90 - GENERAL................1187
Hydraulic diagram; component locations................1188
Hydraulic diagram 1................1193
Hydraulic pressure; testing................1195
Hydraulic system; tightening torques................1197
98 - FUNCTION FOR ROAD CONSTRUCTION................1198
Water pump; removing................1199
Water pump; installing................1202
Water tank; removing................1205
Water tank; installing................1208
Asphalt Compactors DD110C Volvo Repair Service Manual
