Volvo Soil Compactors SD116F Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Soil Compactors SD116F, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Soil Compactors SD116F 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 SD116F Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 860 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL....2
00 - DESCRIPTION; COMPLETE MACHINE....3
Description; complete machine....4
Location of components....8
Machine identification....11
Engine; identification....13
03 - SPECIFICATIONS....14
Specifications; general....15
Tightening torque; specifications_{39-44}....16
Tightening torque; specifications_{39-22}....18
Conversion tables....21
Thread locking compound; application_specifications....29
Machine dimensions....32
Machine weight; specifications....34
Critical mounting torques....35
Battery; specifications....37
Fuel; lubricant and filling capacities....38
Cooling system; specifications....39
Air conditioning; specification....40
Engine; specifications....41
Electrical system; specifications....42
Battery; specifications_34-22....43
Hydrostatic drive; specifications....44
Hydraulic pump; specifications....45
Hydraulic motor; specifications....47
Gear reducer; specifications....48
Brakes; specifications....49
Steering system; specifications....50
Frame link_articulation; specifications....51
Drum; specifications....52
Tyre sizes and pressures specifications....53
Hydraulic connections; tightening torques....54
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION....57
Travelling on public road....58
Transporting the machine....59
Operation numbers for additional work....62
08 - TOOL....64
E-7001....65
1 - STANDARD PARTS; SERVICE....67
16 - LUBRICANT; FUEL; OTHER FLUID....68
Recommended lubricants....69
Environmentally safe handling....73
Lubricant recommendation....75
Oil and filtration....76
Alternative fuels....78
Coolant mixture....81
17 - SERVICE....82
Arrival Inspection; according to Inspection Programme....85
Delivery Inspection; according to Inspection Programme....86
Maintenance of Stored Machines; according to Inspection Programme....87
Maintenance service; every 10 hours....88
Maintenance service; every 50 hours....89
Maintenance service; every 500 hours....91
Maintenance service; every 1000 hours....93
Maintenance service; every 2000 hours....95
Maintenance service; every 3000 hours....97
Maintenance service; first 50 hours....99
Transfer gearbox; filling and checking....101
Cleaning prior to repair....103
Cleaning engine compartment....105
Engine hood; opening ....107
Precaution when working on the electrical system....110
Electric welding....111
Engine oil level; check....112
Coolant level; check....115
Lap type seat belt; checking and maintenance....117
Fuel line; water separator; check and drain....118
Parking brake performance....120
Cooling system integrity; check....123
Battery disconnect switch (main switch); check....124
Steering cylinder pins; greasing....127
Coolant; changing....129
Cooling fan; check....133
Radiator and coolers; cleaning....135
Fan belt and_or alternator belt; checking and adjusting tension....137
Belt tension; checking....139
Axles; checking oil level....140
Axle hubs; checking oil level....142
Transfer gearbox; changing oil....144
Drum drive (torque hub); checking oil level....146
Carrier seal; greasing....148
Drum; checking....149
Drum shock mounts; checking....151
Drum eccentric; checking oil level....153
Drum carrier; checking oil level....155
Scraper; adjusting....158
Lamp (indicator light); checking....160
Ratchet jack; greasing....161
Swivel joint (horizontal and vertical) pins; greasing....163
Articulation (Vertical swivel pin); torque....166
Oscillation (Horizontal swivel pin); torque....168
Wheel nuts; check torque....170
Hydraulic system; checking oil level....172
Hydraulic oil filter; changing....174
Hydraulic oil tank; changing oil and filter....176
Hydraulic tank breather filter; clean....178
Hydraulic oil suction strainer; cleaning....180
Engine; air cleaner maintenance....183
Air cleaner primary filter; clean....185
Battery; maintenance....190
Axle breather; cleaning....193
Carrier breather; cleaning....195
Engine oil and filter; changing....197
Air cleaner; primary filter replacing....200
Air cleaner; secondary filter replacing....202
Fuel filters; replacing....205
Rear axle oil; changing....207
Axle hubs; changing oil....210
Drum drive (torque hub); changing oil....213
Drum carrier; changing oil....216
Drum eccentric; changing oil....219
Tyres; wear and air pressure; checking....222
Hydraulic oil tank; filling....224
Fuel system; bleeding....226
Towing a disabled machine....228
Starting with booster batteries....229
Parking brake; manually releasing....231
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....232
19 - GENERAL....234
Safety concerns everybody!_{48-04}....235
Safety concerns everybody!_{47-39}....239
Safety when handling the machine....241
Safe operation of the machine....244
Stopping....248
Safety when servicing....249
Service position 1....252
Fire prevention measures....256
Health hazards with paint; plastics and rubber....259
Check list after fire or heat exposure....261
Some simple rules regarding tyre handling....263
Safety when lifting and supporting complete machine....265
Transporting the machine....269
Safety when working on the electrical system....272
Safety when working with air conditioning refrigerant....274
Safety when working on hydraulic systems....277
Environmental handling for the future....279
Environmental requirements....281
Waste handling....282
Environmentally safe handling....283
Environmentally hazardous fluids....286
Working in environmentally contaminated areas....287
Handling hazardous materials....288
Decontamination....291
2 - ENGINE WITH MOUNTING AND EQUIPMENT....293
20 - GENERAL....294
Engine; description....295
Engine; symptom troubleshooting....296
Engine does not start....298
Engine difficult to start....299
Heavy exhaust smoke development....300
Engine overheated....301
WARNING Low Engine Oil Pressure....302
21 - ENGINE....303
Engine; removing....304
Engine; installing....309
Valves; adjusting....314
Engine mounting; front; replacing....315
Engine mounting rear; changing....316
23 - FUEL SYSTEM....318
Fuel tank; description....319
Fuel tank; replacing_{28-59}....322
Fuel tank; replacing_{28-35}....325
25 - INLET & EXHAUST SYSTEM....328
Silencer; replacing....329
Exhaust pipe; changing pipe between silencer and turbocharger....331
Air cleaner; removing....334
Air cleaner; installing....336
Air cleaner; description....338
Charge air cooler; description....341
Charge air cooler; removing....343
Charge air cooler; installing....346
Charge air cooler connection (hose; tube); replacing....348
26 - COOLING SYSTEM....350
Cooling system; description....351
Radiator; removing....352
Radiator; installing....356
Fan shroud; replacing....360
Cooling fan; replacing....362
Fan belt and_or alternator belt; replacing....364
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....368
30 - GENERAL....369
Electrical system; component overview_{13-24}....370
Electrical system; component overview_{12-54}....372
Electrical system; component overview_{12-29}....375
Electrical system; component overview_{12-04}....378
Electrical system; component overview_{11-40}....381
Electrical system; specifications....383
Troubleshooting; general....384
Engine does not start....386
INFO Low Voltage....387
Electrical troubleshooting....388
Troubleshooting; electrical control box....390
Variable vibration control....393
Traction control....396
31 - BATTERY....400
Battery; specifications....401
Batteries; replacing....402
32 - ALTERNATOR; CHARGE REGULATOR....405
Alternator; description....406
Alternator; replacing incl function checking....407
33 - STARTING SYSTEM....410
Starter motor; description....411
Starter motor; replacing....412
Starter switch (engine start switch); replacing....414
36 - OTHER ELECTRICAL EQUIPMENT....417
Reverse alarm; replacing....418
Windscreen wiper front motor; replacing....420
Windscreen wiper rear; replacing motor....423
37 - CABLE; FUSE; RELAY....426
Wiring diagram 1 MAIN - Image....427
Wiring diagram 2 - Image....428
Wiring diagram 3 - Image....429
Wiring diagram 4 - Image....430
Wiring diagram 5 - Image....431
Colour codes....432
Wiring diagram index....434
Wiring diagram 1 Main diagram....435
Wiring diagram 2....438
Wiring diagram 3....441
Wiring diagram 4....444
Wiring diagram 5....447
Cable; Battery isolation switch....450
Component list; fuses....452
Component list; relays....454
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....456
Instruments and controls; overview....457
Control unit; description....460
Engine oil pressure sensor; replacing_{53-08}....462
Engine oil pressure sensor; replacing_{52-44}....464
Hydraulic oil temperature sensor; replacing....466
Fuel level sender; replacing....468
4 - POWER TRANSMISSION....470
40 - GENERAL....471
Power Transmission; Propulsion....472
Power train; related components....476
Travel hydraulics; troubleshooting....478
42 - TRANSMISSION; HYDRAULIC CONTROL....480
Two speed valve and solenoid; description....481
Two speed valve solenoid and cartridge; replacing....483
Pump de-stroke valve and solenoid; description....485
Pump de-stroke valve solenoid and cartridge; replacing....487
44 - HYDROSTATIC DRIVE....489
Hydrostatic controller; removing....490
Hydrostatic controller; installing....494
Rear axle drive motor; description....499
Drum drive motor; description....502
Hydraulic hose routing and fitting orientation diagrams....505
Travel motor; replacing....508
Rear axle motor speed sensor; replacing....511
Drive motor; removing....513
Drive motor; installing....516
Drum drive motor speed sensor; replacing....520
Thermal bypass valve; description....522
Thermal bypass valve; replacing....524
Hydrostatic pump; description....526
Loop flushing valve; description....529
Loop flushing valve; replacing....532
Loop flushing valve cartridge; replacing....534
Hydrostatic pump; removing_{34-56}....536
Hydrostatic pump; removing_{34-31}....540
Hydrostatic pump; installing....544
Pump coupling; removing....547
Pump coupling; installing....549
Traction control valve; description....551
Traction valve; solenoid and cartridge; replacing....554
46 - FRONT AXLE; REAR AXLE....557
Rear axle; description....558
Axle; removing....560
Axle; installing....563
5 - BRAKE....566
52 - HYDRAULIC BRAKE SYSTEM....567
Hydraulic brake system; description....568
55 - PARKING BRAKE....569
Parking brake; description....570
Multi function brake valve solenoid and cartridge; replacing....571
Parking brake pressure switch; replacing....573
6 - STEERING....575
64 - STEERING....576
Steering system; description....577
Steering system; component location....579
Steering system; symptom troubleshooting....581
Adjustable steering column; replacing....583
Steering control unit; removing....587
Steering control unit; installing....590
Steering pump; removing....592
Steering pump; installing....594
Steering cylinder; removing....596
Steering cylinder; installing....600
Steering control unit; description and operation....604
Steering pressure; checking and adjusting....606
Steering pump; description....608
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....611
71 - FRAME....612
Frame; description....613
74 - FRAME LINK....615
Frame joint; Replacing the front pivot bearing with machine separated....616
Frame joint; replacing the rear pivot bearing with machine separated....631
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....638
Wheels; tightening torques....639
Drum eccentric; description....640
Vibration motor; description....643
Vibration pump; description....645
Vibration hydraulic circuit; description....647
Vibration system; component location....649
Wheel; removing and fitting one....651
Drum; description....654
Drum; removing....657
Drum; installing_{10-28}....663
Drum; installing_{10-03}....668
Eccentric weight; removing....673
Eccentric weight; installing....676
Drum shock mount; replacing....678
Vibration motor; removing....680
Vibration motor; installing....682
Vibration pump; removing....685
Vibration pump; installing....687
Eccentric weight; overhauling....689
Eccentric shaft coupling; replacing....691
Eccentric weight bearings; replacing....693
Torque hub; removing....695
Torque hub; installing....698
Carrier bearings; replacing....700
Drum bolt-on shell option; installing....704
Smooth drum scrapers; replacing....709
Padfoot drum scrapers; replacing....711
Vibration system; troubleshooting....713
Vibration speed sensor; replacing....715
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....717
81 - CAB; NAKED; CANOPY....718
Cab; component locations....719
Operator's protective structure; description....722
Operator's platform; raising....725
Operator's platform; lowering....729
Viscous cab suspension; changing all units....734
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....740
Engine hood; opening....741
Engine hood; removing....744
Engine hood; installing....747
Engine hood; changing spring....749
85 - CAB INTERIOR; UPHOLSTERY....752
Operator's seat; removing....753
Operator's seat; installing....755
87 - AIR CONDITIONING UNIT....757
Climate control system; description....758
Cooler and Heater assembly; removing....759
Cooler and Heater assembly; installing....763
Cab filter; replacing....767
Fan motor; replacing....769
Heater core; replacing....772
Heat control valve; replacing....776
Heater unit relays; replacing....779
Compressor; replacing incl draining and filling....781
Compressor; replacing magnetic clutch (compressor removed)....784
Condenser; replacing incl draining and filling....787
Receiver; replacing incl draining and filling....790
Switch; replacing....792
Evaporator; replacing incl draining and filling....794
Thermostat; replacing....798
HVAC control switch; replacing_{47-12}....803
HVAC control switch; replacing_{46-51}....805
88 - INTERIOR EQUIPMENT....807
Seat safety belt; replacing....808
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....810
90 - GENERAL....811
Hydraulic diagram components list; standard - Image....812
Hydraulic diagram components list; with option - Image....813
Hydraulic main diagram (Standard machine) - Image....814
Hydraulic diagram; with option components - Image....815
Explanations to hydraulic diagram....816
Hydraulic diagram components list; standard....823
Hydraulic diagram components list; with option....825
Hydraulic main diagram (Standard machine)....827
Hydraulic diagram; with option components....831
Oil and filtration....835
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....837
Working hydraulic system; description....838
Hydraulic oil tank; description....842
Hydraulic oil tank; changing oil and filter incl.cleaning tank....845
Hydraulic oil tank; removing....847
Hydraulic oil tank; installing....849
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump....851
Hydraulic oil cooler; description....853
Hydraulic oil cooler; removing....855
Hydraulic oil cooler; installing....858
Volvo Soil Compactors SD116F Repair Service Manual
