Volvo Asphalt Compactors DD90B Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Asphalt Compactors DD90B, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Asphalt Compactors DD90B 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 Asphalt Compactors DD90B Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 770 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
0 - GENERAL........2
00 - DESCRIPTION; COMPLETE MACHINE........3
Complete machine; descriptions........4
Location of components........7
Starting engine........9
Stopping........10
03 - SPECIFICATIONS........11
Measurement conversion tables........12
Glossary of Abbreviations........16
Volvo standard tightening torques........17
Machine weights........20
Fuel; lubricant and filling capacities........21
Thread locking compound; application_specifications........22
07 - STANDARD TIME........23
Operation numbers for additional work........24
08 - TOOL........26
E-7013........27
E-7033........28
E-7034........30
E-7035........31
1 - STANDARD PARTS; SERVICE........32
16 - LUBRICANT; FUEL; OTHER FLUID........33
Recommended lubricants........34
Alternative fuels........36
17 - SERVICE........39
Service and maintenance........41
Arrival Inspection; according to Inspection Programme........42
Delivery Inspection; according to Inspection Programme........43
Maintenance of Stored Machines; according to Inspection Programme........44
Drum and scraper; checking........45
Spray bars; cleaning........47
Maintenance service; as required........49
Maintenance service; every 10 hours........50
Maintenance service; every 50 hours........51
Maintenance service; every 250 hours........52
Maintenance service; every 1000 hours........54
Maintenance service; every 2000 hours........56
Service position 1........58
Lubrication; every 50 hours........61
Lubrication; every 250 hours........63
Engine oil level; checking........65
Fuel level; checking........67
Water separator; checking........69
Engine air cleaner system integrity; checking........71
Air cleaner restriction indicator; checking........74
Engine air cleaner primary filter; cleaning........76
Engine air cleaner primary filter; replacing........80
Engine air cleaner secondary filter; replacing........83
Engine pre cleaner cyclone type; cleaning........86
Coolant level; checking........88
Coolant; changing........90
Cooling system integrity; checking........94
Battery system integrity; checking........97
Articulation pin torque; checking........99
Drum eccentric oil level; checking........101
Drum eccentric oil; changing........103
Drum carrier oil level; checking........105
Drum carrier oil; changing........107
Drum carrier breather; cleaning........110
Hydraulic oil level; checking........112
Hydraulic oil; changing........113
Hydraulic oil suction strainer; cleaning........115
Hydraulic oil filters; replacing........118
Water tank level; checking........121
Water tank; cleaning........122
Water pump filter; checking........124
Starting with booster batteries........126
19 - GENERAL........128
Service position 1........129
Safety concerns everybody!........132
General........133
Precautions........134
A few simple safety rules........135
Safety when handling the machine........136
Before service; read........137
Before operating........138
Electrical system........139
Fire prevention measures........140
Check list after fire or heat exposure........143
Safety when handling oil and fuel........144
Safety when lifting and supporting complete machine........145
Safety when working on hydraulic systems........146
Safety when working with batteries........147
Cleanliness........149
Environment........150
Environmental handling for the future........151
Environmentally safe handling........152
Health hazards with paint; plastics and rubber........154
Working in environmentally contaminated areas........156
Decontamination........157
Waste handling........158
2 - ENGINE WITH MOUNTING AND EQUIPMENT........159
20 - GENERAL........160
Engine; description........161
Engine weight; specifications........162
Engine; component locations........163
Engine; tightening torque........165
21 - ENGINE........166
Engine; specifications........167
Valve system; specifications........168
Valves; description........169
22 - LUBRICATING SYSTEM........171
Lubrication system; specifications........172
Lubrication system; description........173
Lubrication system; component locations........175
23 - FUEL SYSTEM........177
Fuel system; tightening torques........178
Fuel system; description........179
Fuel tank sight gauge; replacing........181
Fuel tank lid; replacing........183
Fuel pipes; replacing........185
25 - INLET & EXHAUST SYSTEM........188
Inlet and exhaust system; specifications........189
Inlet and exhaust system; description........190
Flexible pipe; replacing........193
Silencer; replacing........196
Turbocharger; description........198
Air cleaner; removing........200
Air cleaner; installing........203
Pre-cleaner; replacing........206
26 - COOLING SYSTEM........207
Cooling system; description........208
Cooling system; component locations........211
Cooling package; removing........213
Cooling package; installing........219
Radiator hose upper; replacing........226
Radiator hoses lower; replacing........229
Radiator; replacing........232
Expansion tank; replacing........234
Cooler top shock mount; replacing........236
Cooler bottom shock mount; replacing........238
Belt tension; specifications........242
Cooling fan; replacing........243
Fan shroud; replacing........247
27 - ENGINE CONTROL........254
Throttle control cable; removing........255
Throttle control cable; installing........259
Throttle control lever; replacing........264
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........266
30 - GENERAL........267
Electrical system; instructions........268
Electrical system; description........269
Electrical system; specifications........270
Check the relay for failure.........271
Check the fuse for failure.........274
31 - BATTERY........276
Battery; storage........277
Battery; description........278
Battery; specifications........279
Battery; charging........280
Batteries; replacing........282
32 - ALTERNATOR; CHARGE REGULATOR........284
Alternator; specifications........285
Alternator; description........286
33 - STARTING SYSTEM........287
Starter motor; specifications........288
Starter motor; description........289
35 - LIGHTING........290
Lights; specifications........291
Component location; lights........292
Headlamp; replacing........294
Tail lamp; replacing........296
Licence plate lamp; replacing........298
Interior lamp; replacing........300
Work lamp; replacing........302
36 - OTHER ELECTRICAL EQUIPMENT........304
Back-up alarm; specifications........305
Electric horn; specifications........306
Back-up alarm; description........307
Electric horn; description........308
Horn; replacing........309
Back up alarm; replacing........311
Horn switch; replacing........313
Dual function alarm; replacing........315
Power socket; replacing........317
Switch; replacing........319
Component list; Switches........321
Reverse alarm switch; replacing........322
Emergency stop switch; replacing........324
Ignition switch; replacing........326
Diode; replacing........328
37 - CABLE; FUSE; RELAY........330
Electrical symbols and designations........332
Component list; diodes........334
Component list; fuses........336
Component list; relays_{14-01}........337
Component list; relays_{13-40}........338
Wiring diagram index_{13-01}........339
Wiring diagram index_{12-39}........346
Wiring diagram WD301_{12-05}........353
Wiring diagram WD301_{11-40}........356
Wiring diagram WD302_{10-58}........359
Wiring diagram WD302_{10-33}........362
Wiring diagram WD303_{09-56}........365
Wiring diagram WD303_{09-32}........368
Wiring diagram WD304_{08-55}........371
Wiring diagram WD304_{08-30}........373
Wiring diagram WD305_{07-42}........376
Wiring diagram WD305_{07-17}........379
Wiring diagram WD306_{06-41}........382
Wiring diagram WD306_{06-16}........385
Wiring diagram WD307_{05-39}........388
Wiring diagram WD307_{05-15}........391
Wiring diagram WD308_{04-38}........394
Wiring diagram WD308_{04-13}........397
Wiring diagram WD309_{03-37}........400
Wiring diagram WD309_{03-12}........403
Wiring diagram WD310_{02-35}........406
Wiring diagram WD310_{02-11}........409
Wiring diagram WD311_{01-34}........412
Wiring diagram WD311_{01-09}........415
Wiring diagram WD312_{00-33}........418
Wiring diagram WD312_{00-08}........421
Battery disconnect switch; description........424
Engine wire harness; replacing........425
Battery disconnect switch; replacing........428
FSR wiring harness; replacing........430
Rear wire harness; replacing........433
Main wire harness; replacing........436
Front wire harness; replacing........444
Battery cable negative; replacing........447
Battery cable +; replacing........450
Console wiring harness; replacing........453
Work light harness; replacing........457
Relay and fuse wiring harness; replacing........460
Fuse (general); replacing........463
Relay (general); replacing........465
Component location; fuses and relays........467
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........469
Water flow control; replacing........470
Hour meter; replacing........472
4 - POWER TRANSMISSION........474
40 - GENERAL........475
Power transmission; specifications........476
42 - TRANSMISSION; HYDRAULIC CONTROL........477
Two speed solenoid valve; replacing........478
Neutral safety switch; replacing........481
Propulsion control cable; replacing........483
Control group assembly; replacing........489
44 - HYDROSTATIC DRIVE........493
Drum drive motor; description........494
Propulsion pump; description........496
Two speed travel system; description........498
Propulsion pump; removing........499
Propulsion pump; installing........502
5 - BRAKE........506
50 - GENERAL........507
Brake system; specifications........508
Brake system; description........509
52 - HYDRAULIC BRAKE SYSTEM........510
Brake valve; specification........511
Brake valve; description........512
Brake valve; replacing........513
55 - PARKING BRAKE........516
Parking brake pressure switch; replacing........517
6 - STEERING........520
60 - GENERAL........521
Steering system; specifications........522
Steering system; description........523
Steering valve; description........527
Steering system; troubleshooting........529
64 - STEERING........532
Steering column; removing........533
Steering column; installing........535
Steering wheel; replacing........537
Steering cylinder; replacing........538
Steering valve; removing........541
Steering valve; installing........543
Steering cylinder bearings; replacing........545
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........547
71 - FRAME........548
Frame; specifications........549
Frame; description........550
Frame; tightening torques........551
74 - FRAME LINK........552
Articulation pin; removing........553
Articulation pin; installing........556
Articulation bearings; replacing........560
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........563
Vibration motor; specifications........564
Vibration pump; specifications........565
Drum eccentric; description........566
Vibration motor; description........567
Vibration pump; description........569
Drum; tightening torques........571
Drum; description........574
Carrier; removing........576
Carrier; installing........580
Drum drive motor; replacing........584
Smooth drum scrapers; replacing........587
Vibration motor; removing........589
Vibration motor; installing........591
Vibration pump; removing........593
Vibration pump; installing........597
Instructions for shimming the equipment joints........601
Vibration control valve; replacing........605
Drum; specifications........608
Drum assembly (rear); removing........609
Drum assembly (rear); installing........613
Drum assembly (front); removing........617
Drum assembly (front); installing........622
Drum drive; removing........628
Drum drive; installing........630
Carrier bearings; replacing........632
Drum shock mount (single); replacing........637
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........639
80 - GENERAL........640
Operator's protective structure; description........641
81 - CAB; NAKED; CANOPY........643
Canopy; removing........644
Canopy; installing........647
Operator's platform; removing........650
Operator's platform; installing........660
Operator's platform mounts; replacing........670
82 - ENGINE HOOD; MUDGUARD; FOOT STEP........673
Cowl frame; removing........674
Cowl frame; installing........682
Hand rail; removing........690
Hand rail; installing........691
83 - DOORS; HATCH; COVER PLATE; (all)........692
Deck plate; removing........693
Deck plate; installing........694
85 - CAB INTERIOR; UPHOLSTERY........695
Seat belt; replacing........696
Operator's seat; removing........698
Operator's seat; installing........700
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........702
90 - GENERAL........703
Hydraulic diagram 1 - Image........704
Explanations to hydraulic diagram........705
Hydraulic diagram; component locations........708
Hydraulic diagram 1........710
Hydraulic system; specifications........714
Hydraulic oil; description........715
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........717
Hydraulic oil tank; removing........718
Hydraulic oil tank; installing........724
Hydraulic oil cooler; replacing........730
Hydraulic tank shock mount; replacing........732
Hydraulic oil level gauge; replacing........734
Hydraulic tank lid cover plate gasket; replacing........736
Working hydraulic system; description........738
Working hydraulic pressure; checking........745
98 - FUNCTION FOR ROAD CONSTRUCTION........752
Water spray system; specifications........753
Water pump; removing........754
Water pump; installing........756
Water tank; removing........758
Water tank; installing........760
Water spray system components; replacing........763
Water strainer; replacing........765
Ball valve; replacing........767
Water spray system; component location........769
Foreword........770
Volvo Asphalt Compactors DD90B Repair Service Manual
