Volvo Soil Compactors SD115B Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Soil Compactors SD115B, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Soil Compactors SD115B 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.
Volvo Soil Compactors SD115B Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,489 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torque; specifications_{57-39}....5
Tightening torque; specifications_{57-20}....8
Thread locking compound; application_specifications....11
Hydraulic connections; tightening torques....13
07 - STANDARD TIME....16
Operation numbers for additional work....17
08 - TOOL....19
E-7021....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_{51-01}....45
Recommended lubricants_{50-32}....46
Alternative fuels....50
17 - SERVICE....53
Tech Tool; operations-....56
Service and Maintenance Introduction....58
Arrival Inspection; according to Inspection Programme....59
Delivery Inspection; according to Inspection Programme....60
Maintenance of Stored Machines; according to Inspection Programme....61
Maintenance service; first 100 hours....62
Maintenance service; every 10 hours....63
Maintenance service; every 50 hours....64
Maintenance service; every 500 hours_{45-50}....66
Maintenance service; every 1000 hours_{45-22}....68
Maintenance service; every 2000 hours_{44-53}....71
Maintenance service; every 3000 hours_{44-25}....74
Maintenance service; every 6000 hours_{43-56}....77
Maintenance service; every 8000 hours....78
Service position-....79
Lubrication; every 50 hours....81
Lubrication; every 500 hours....86
Leakage; checking....88
Engine belt tension; checking....89
Engine belt condition; checking....90
Valves; adjusting_{40-29}....92
Valves; adjusting_{39-59}....96
Engine oil level; checking....102
Engine oil and filter; changing_{38-11}....104
Water separator; checking....107
Fuel filter; replacing....109
Water separator filter; replacing....111
Fuel tank breather filter; replacing....113
Diesel particulate filter; regenerating....115
Diesel particulate filter; checking and cleaning....116
AdBlue®_DEF pump unit filter; replacing....127
AdBlue®_DEF tank breather filter; replacing....130
Engine air cleaner system integrity; checking....132
Engine air cleaner primary filter; cleaning....133
Engine air cleaner primary filter; replacing....136
Engine air cleaner secondary filter; replacing....139
Engine pre cleaner cyclone type; cleaning....142
Coolant level; checking....144
Coolant; changing....145
Coolant freezing point; checking....148
Cooling system integrity; checking....150
Software update; checking....152
Battery system integrity; checking....156
Emergency stop switch; testing....158
Planetary drive oil level; checking_{27-47}....159
Planetary drive oil level; checking_{27-26}....161
Planetary drive oil; changing_{26-55}....163
Planetary drive oil; changing_{26-34}....165
Axle oil; changing....167
Axle hub oil; changing....169
Axle breather filter; cleaning....171
Parking brake function; checking....173
Articulation pin torque; checking....175
Oscillation pin torque; checking....177
Tyre wear and air pressure; checking....180
Wheel nuts torque; checking....182
Drum shock mounts; checking....183
Drum eccentric oil level; checking....184
Drum eccentric oil; changing....186
Drum carrier oil level; checking....188
Drum carrier oil; changing....190
Drum carrier breather; cleaning....192
Cab prefilter; cleaning....194
Cab prefilter; replacing....196
Cab main filter; cleaning....198
Cab main filter; replacing....201
Hydraulic oil level; checking....204
Hydraulic oil; changing....205
Hydraulic oil filters; replacing....207
Hydraulic oil tank breather filter; replacing....209
Levelling blade hydraulic oil filter; replacing....210
19 - GENERAL....212
Safety concerns everybody!....213
Service position....217
Some simple rules regarding tyre handling....219
Safety when handling the machine....221
A few simple safety rules....225
Before operating....229
Before service; read....233
General....237
Cleanliness....242
Electrical system....246
Checklist after a fire or heat exposure....250
Health hazards with paint; plastics and rubber....253
Safety when handling oil and fuel....257
Safety when working with batteries....260
Charging batteries....263
Environment....267
Environmental handling for the future....272
Decontamination....275
Safety when lifting and supporting complete machine....279
2 - ENGINE WITH MOUNTING AND EQUIPMENT....281
20 - GENERAL....282
Engine; description_{04-16}....283
Engine; description_{03-53}....290
Engine; description_{03-32}....296
Tech Tool; operations-0304....298
Engine control module (ECM); replacing pre-programmed_{02-39}....300
Engine control module (ECM); replacing pre-programmed_{02-18}....303
Engine control module (ECM); replacing non-programmed_{01-34}....307
Engine control module (ECM); replacing non-programmed_{01-13}....310
Engine; reference values....314
Engine belt; removing_{00-24}....316
Engine belt; removing_{00-03}....318
Engine belt; installing_{59-33}....321
Engine belt; installing_{59-12}....323
21 - ENGINE....325
Engine; specifications....326
Engine rotation speed sensor (crank shaft); replacing_{57-48}....328
Engine rotation speed sensor (crank shaft); replacing_{57-27}....331
Engine rotation speed sensor (camshaft); replacing....334
Engine; tightening torques_{56-30}....336
Engine; tightening torques_{56-10}....338
Engine; tightening torques_{55-48}....339
Cylinder compression; testing....348
Crankcase ventilation; description....351
Valves; adjusting_{52-26}....355
Valves; adjusting_{51-59}....359
Valve cover; removing....365
Valve cover; installing....368
22 - LUBRICATING SYSTEM....371
Lubrication system; description_{48-28}....372
Lubrication system; description_{48-06}....377
Lubrication system; specifications....379
Lubrication system; component locations_{47-09}....381
Lubrication system; component locations_{46-48}....383
Lubrication system; tightening torques....385
Lubrication oil pressure; checking with pressure gauge_{44-51}....388
Lubrication oil pressure; checking with pressure gauge_{44-30}....392
23 - FUEL SYSTEM....396
Fuel system; description_{43-00}....397
Fuel system; description_{42-33}....405
Fuel system; specifications....407
Fuel system; tightening torques_{41-44}....409
Fuel system; tightening torques_{41-10}....417
Carbon dioxide in fuel system; checking....418
Fuel system; component location_{40-24}....424
Fuel system; component location_{40-03}....427
Fuel pump; replacing_{38-46}....429
Fuel pump; replacing_{38-25}....432
Fuel system; bleeding....434
Injectors; replacing_{36-37}....436
Injectors; replacing_{36-15}....442
Fuel rail; replacing_{35-45}....444
Fuel rail; replacing_{35-24}....447
Fuel rail pressure sensor; replacing....451
High pressure fuel pump; replacing_{34-22}....453
High pressure fuel pump; replacing_{33-58}....456
High pressure fuel pipes; replacing_{33-28}....459
High pressure fuel pipes; replacing_{33-07}....461
Fuel control valve (FCV); replacing_{32-37}....465
Fuel control valve (FCV); replacing_{32-16}....471
Pressure relief valve (PRV); replacing....476
25 - INLET & EXHAUST SYSTEM....478
Inlet and exhaust system; description_{30-00}....480
Inlet and exhaust system; description_{29-35}....487
Inlet and exhaust system; specification....488
Inlet and exhaust system; component location_{28-48}....490
Inlet and exhaust system; component location_{28-27}....493
Inlet and exhaust system; tightening torques_{27-57}....495
Inlet and exhaust system; tightening torques_{27-36}....497
Inlet and exhaust system; tightening torques_{27-04}....503
Exhaust pipe flexible tube; replacing....505
Exhaust Aftertreatment System; description....510
Exhaust Aftertreatment System; component location....523
Regeneration process; description....526
AdBlue®_DEF dosing injector; replacing....533
AdBlue®_DEF mixing tube; replacing....537
AdBlue®_DEF tank; replacing....546
AdBlue®_DEF; draining....551
Coolant valve; replacing....553
SCR (Selective catalytic reduction) muffler; replacing....556
AdBlue®_DEF quality; checking....559
SCR (Selective catalytic reduction) dosing system; checking....562
AdBlue®_DEF pump unit diagnostics; description....566
DPF (Diesel particulate filter); checking and cleaning....570
ACM (Aftertreatment control module) non-programmed; replacing....571
ACM (Aftertreatment control module) pre-programmed; replacing....573
Inlet throttle; replacing....575
DOC (Diesel oxidation catalyst); replacing....578
Muffler; replacing....589
AdBlue®_DEF pump unit; replacing....595
AdBlue®_DEF tank armature; replacing....600
AdBlue®_DEF tank armature; cleaning....605
AdBlue®_DEF tank armature suction filter; replacing....608
AdBlue®_DEF....610
Crystallization of AdBlue®_DEF; checking....616
AdBlue®_DEF pump unit; flushing....621
AdBlue®_DEF pump unit; inlet nipple; replacing....624
Regeneration log; checking....627
Turbocharger; replacing_{11-27}....639
Turbocharger; replacing_{11-06}....644
Wastegate; checking....650
Air cleaner; removing....652
Air cleaner; installing....654
Preheating coil; replacing_{08-50}....656
Preheating coil; replacing_{08-20}....662
26 - COOLING SYSTEM....664
Cooling system; description....665
Cooling system; specifications....669
Carbon dioxide in coolant system; checking....671
Cooling system; component location....677
Cooling system; tightening torques_{05-32}....680
Cooling system; tightening torques_{05-11}....682
Fan pump; specifications....684
Coolant pump; replacing_{04-19}....685
Coolant pump; replacing_{03-58}....689
Thermostat; replacing_{02-42}....693
Thermostat; replacing_{02-21}....696
Cooling fan; description....699
Fan pump; removing....704
Fan pump; installing....706
29 - MISCELLANEOUS....709
Exhaust Gas Recirculation (EGR); description....710
Exhaust gas recirculation (EGR); component location....716
EGR system; tightening torques....718
EGR reed valve; replacing....720
EGR cooler; replacing....728
EGR actuator; replacing....734
EGR venturi tube; replacing....739
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....744
30 - GENERAL....745
Tech Tool; operations ....749
General fault diagnosis information....750
Troubleshooting strategy....751
Collection of basic data....753
Conditions when checking....755
Lead and connector checks....757
Troubleshooting tools....761
Tech Tool Service Tool....762
Tech Tool; operations....765
BB1 Communication bus; description and measuring....766
BB2 Communication bus; description and measuring....769
FX1007; description and measuring....772
FX1074; description and measuring....774
FX1079; description and measuring....777
HE2501; description and measuring....779
HE2511; description and measuring....780
HE2512; description and measuring....782
HE2513; description and measuring....784
IC2; description and measuring....786
MA2301-MA2304; description and measuring....789
MA2517; description and measuring....791
MA2519; description and measuring....793
MA4202; description and measuring....794
MA4212; description and measuring....796
MA4407; description and measuring....797
MA4410; description and measuring....798
MA9151; description and measuring....800
MO2503; description and measuring....801
MO3301; description and measuring....803
Power supply; ACM (Aftertreatment Control Module); description and measuring....805
Power supply ECM; description and measuring....807
Power supply GPMECU 1; description and measuring....809
Power supply HMICU; description and measuring....811
PWM2303; description and measuring....813
PWM9150; description and measuring....815
PWM9426; description and measuring_{25-39}....817
PWM9426; description and measuring_{25-06}....819
PWM9427; description and measuring_{24-23}....821
PWM9427; description and measuring_{23-48}....823
PWM9430; description and measuring....825
PWM9431; description and measuring....827
RE3705; description and measuring....829
SAE J1939-1 SubNet 1; description and measuring....832
SE2203; description and measuring....835
SE2301; description and measuring....837
SE2302; description and measuring....839
SE2303; description and measuring....840
SE2309; description and measuring....842
SE2502; description and measuring....843
SE2507; description and measuring....845
SE2511; description and measuring....847
SE2512; description and measuring....848
SE2513; description and measuring....850
SE2515; description and measuring....852
SE2516; description and measuring....854
SE2519; description and measuring....856
SE2521; description and measuring....858
SE2522; description and measuring....860
SE2533; description and measuring....862
SE2543; description and measuring....865
SE2544; description and measuring....867
SE2603; description and measuring....869
SE2604; description and measuring....871
SE2606; description and measuring....873
SE2701; description and measuring....875
SE2703; description and measuring....877
SE5501; description and measuring....879
SE8701; description and measuring....881
SE8702; description and measuring....883
SE8705; description and measuring....885
SE9105; description and measuring....887
SE9426; description and measuring....889
SE9428; description and measuring....891
SE9429; description and measuring....893
SE9600; description and measuring....895
SE9601; description and measuring....898
Multimeter 8889 0074....901
Test pins 999 0008....902
Adapter cable 999 0020....903
Extension cable 999 0062....904
Adapter cable 999 3893....905
Multi-pin breaker box 999 8699....906
Template 8889 0019....907
Adapter cable 999 0014....908
Adapter cable 999 0216....909
Component fault diagnosis; description....910
Test methods; description....913
Traction control error codes; description....917
Vibration control error code; description....919
32 - ALTERNATOR; CHARGE REGULATOR....921
Alternator; description....922
Alternator; removing_{40-58}....925
Alternator; removing_{40-38}....929
Alternator; installing_{40-08}....932
Alternator; installing_{39-47}....936
33 - STARTING SYSTEM....939
Starting system; description....940
Starter motor; tightening torques....944
36 - OTHER ELECTRICAL EQUIPMENT....947
GPMECU; changing non-programmed ECU....948
GPMECU; changing pre-programmed ECU....951
HMICU non-programmed; replacing....954
HMICU pre-programmed; replacing....957
37 - CABLE; FUSE; RELAY....960
Electrical symbols and designations....962
Explanation of wiring diagrams....966
Component list; Diodes....969
Component list; fuses....970
Component list; Miscellaneous....972
Component list; motors....974
Component list; relays....975
Component list; sensors....977
Component list; Solenoid valves....979
Component list; Switches....980
ACM; I_O list....985
CU8710; I_O list....988
E-ECU; I_O list....990
GPM-ECU; I_O list....994
HMICU; I_O list....998
W-ECU; I_O list....1000
Wiring diagram index....1001
Wiring diagram 1....1002
Wiring diagram 2....1005
Wiring diagram 3....1008
Wiring diagram 4....1011
Wiring diagram 5....1013
Wiring diagram 6....1016
Wiring diagram 7....1019
Wiring diagram 8....1022
Wiring diagram 9....1025
Wiring diagram 10....1028
Wiring diagram 11....1031
Wiring diagram 12....1034
Wiring diagram 13....1037
Wiring diagram 14....1040
Wiring diagram 15....1043
Wiring diagram 16....1046
Wiring diagram 17....1049
Wiring diagram 18....1052
Wiring diagram 19....1055
Wiring diagram 20....1058
Wiring diagram 21....1061
Wiring diagram 22....1064
Wiring diagram 23....1067
Positive feed....1070
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1071
Compact assist; functional description....1072
Volvo Co-Pilot; description....1075
Volvo Co-Pilot; component location....1077
Volvo Co-Pilot; replacing....1078
Volvo Co-Pilot SIM card; installing....1081
Volvo Co-Pilot Android software; updating online (OtA)....1085
Volvo Co-Pilot Android software; updating offline (USB)....1087
Volvo Co-Pilot Android software offline (USB) update; checking....1090
Smart Receiver; replacing....1092
GNSS Antenna; replacing....1094
Inertial measurement unit (IMU); replacing....1096
4 - POWER TRANSMISSION....1099
42 - TRANSMISSION; HYDRAULIC CONTROL....1100
Propulsion control lever; replacing....1101
44 - HYDROSTATIC DRIVE....1105
Propulsion system; tightening torques....1106
Hydrostatic drive system; description....1111
Propulsion pump; description....1115
Propulsion pump; specifications....1117
Axle motor; description....1118
Axle motor; specifications....1120
Drum drive motor; description....1121
Drum drive motor; specifications....1123
Traction control system; description....1124
Traction control valve; description....1127
Traction control microprocessor; description....1129
Brake_shunt valve function; description....1131
Thermal bypass valve; description....1133
Loop flushing valve; description....1135
Thermal bypass valve; specifications....1137
Propulsion planetary; removing_{02-16}....1138
Propulsion planetary; removing_{01-56}....1142
Propulsion planetary; installing_{01-15}....1146
Propulsion planetary; installing_{00-54}....1150
Rear axle drive motor; removing....1154
Rear axle drive motor; installing....1157
Drum drive motor speed sensor; replacing....1159
Rear axle motor speed sensor; replacing....1162
ASC (Anti-spin control) solenoid; replacing....1164
Traction control module; replacing....1166
Propulsion pump; multi function valve; replacing....1168
Charge pressure relief valve; replacing....1170
Traction control valve; replacing....1172
Propulsion pump; removing....1176
Propulsion pump; installing....1179
46 - FRONT AXLE; REAR AXLE....1183
Axle; tightening torques....1184
5 - BRAKE....1186
55 - PARKING BRAKE....1187
Parking brake; function description....1188
Axle brake; specifications....1191
Drum brake; specifications....1192
6 - STEERING....1193
60 - GENERAL....1194
Steering system; specifications....1195
Steering pump; description....1196
Steering system; description....1198
Steering valve; description....1201
Steering; tightening torques....1203
64 - STEERING....1205
Steering cylinder; replacing....1206
Steering pump; removing....1210
Steering pump; installing....1213
Steering valve; replacing....1216
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1219
71 - FRAME....1220
Frame; tightening torques....1221
Drum frame; removing....1224
Drum frame; installing....1228
Swivel; removing....1232
Swivel; installing....1236
74 - FRAME LINK....1240
Frame joint bearings; specifications....1241
Frame joint; replacing bearings....1242
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1245
Vibration motor; specifications....1247
Vibration pump; specifications....1248
Drum vibration; specifications....1250
Wheels; specifications....1251
Wheels; tightening torques....1252
Drum eccentric; description....1253
Vibration motor; description....1256
Vibration pump; description....1259
Vibration system; description_{41-10}....1262
Vibration system; description_{40-49}....1266
Vibration control microprocessor; description....1269
Drum; tightening torques....1271
Wheel; removing....1277
Wheel; installing....1279
Carrier; removing....1281
Carrier; installing....1285
Drum; removing....1289
Drum; installing....1293
Eccentric weight; removing....1297
Eccentric weight; installing....1302
Drum drive motor; replacing....1307
Drum shock mount; replacing....1310
Vibration motor; removing....1312
Vibration motor; installing....1314
Vibration pump; removing....1316
Vibration pump; installing....1320
Eccentric weight; overhauling....1325
Eccentric weight bearings; replacing....1329
Carrier bearings; replacing....1335
Drum drive assembly; removing....1338
Drum drive assembly; installing....1341
Vibration pump charge pressure relief valve; adjusting....1343
Vibration system pressure; checking....1345
Vibration control module; replacing....1349
Vibration pump charge pressure relief valve; replacing....1351
Vibration pump SCR (system check_relief) valve; replacing....1353
Smooth drum scrapers; replacing....1355
Vibration speed sensor; replacing....1357
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1359
81 - CAB; NAKED; CANOPY....1360
Cab; removing....1361
Cab; installing....1368
Operator's platform; tightening torques....1375
Operator's platform; raising....1379
Operator's platform; lowering....1382
87 - AIR CONDITIONING UNIT....1385
Climate control system; description....1386
Air conditioning; specifications....1392
Climate unit; tightening torques....1393
Climate unit; removing....1395
Climate unit; installing....1402
Fan motor; replacing....1409
Air mix door actuator; replacing....1412
Heater core; replacing....1417
Heat control valve; replacing....1419
Air conditioning performance; checking....1424
Cooling unit; leak detection....1426
Drying filter; replacing....1428
Condenser; replacing....1431
Compressor; replacing....1435
Evaporator; replacing....1441
Expansion valve; replacing....1449
Refrigerant; draining....1458
Refrigerant; filling incl vacuum pumping....1461
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1465
90 - GENERAL....1466
Hydraulic system; tightening torques....1467
Hydraulic diagram; component locations....1469
Hydraulic diagram 1_{18-41}....1474
Hydraulic diagram 1_{18-21}....1477
Hydraulic diagram 2....1479
Hydraulic diagram 3_{17-24}....1481
Hydraulic diagram 3_{17-04}....1484
Hydraulic diagram 4....1486
Hydraulic pressure; testing....1488
Volvo Soil Compactors SD115B Repair Service Manual
