Volvo Soil Compactors SD135B Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Soil Compactors SD135B*, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Soil Compactors SD135B 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 SD135B Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,733 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torque; specifications_{34-01}....5
Tightening torque; specifications_{33-49}....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
1 - STANDARD PARTS; SERVICE....35
16 - LUBRICANT; FUEL; OTHER FLUID....36
Recommended lubricants_{29-43}....37
Recommended lubricants_{29-27}....41
Fuel; lubricant and filling capacities_{29-08}....45
Fuel; lubricant and filling capacities_{28-52}....46
Alternative fuels....47
AdBlue®_DEF ....50
17 - SERVICE....58
Scheduled maintenance....61
Tech Tool; Operations ....63
Arrival Inspection; according to Inspection Programme....65
Delivery Inspection; according to Inspection Programme....66
Maintenance of Stored Machines; according to Inspection Programme....67
Maintenance service; first 100 hours....68
Maintenance service; every 10 hours....69
Maintenance service; every 50 hours....70
Maintenance service; every 500 hours_{24-54}....71
Maintenance service; every 500 hours_{24-42}....73
Maintenance service; every 1000 hours_{23-51}....75
Maintenance service; every 1000 hours_{23-39}....77
Maintenance service; every 2000 hours....79
Maintenance service; every 3000 hours....81
Maintenance service; every 6000 hours....82
Maintenance service; every 8000 hours....83
Service position_55-43....84
Lubrication; every 50 hours....86
Lubrication; every 500 hours....91
Leakage; checking....93
Engine belt tension; checking....94
Engine belt condition; checking....95
Valves; adjusting_{37-46}....97
Valves; adjusting_{37-22}....101
Engine oil level; checking....107
Engine oil and filter; changing_{36-33}....109
Water separator; checking....112
Fuel filter; replacing....114
Water separator filter; replacing....116
Fuel tank breather filter; replacing....118
Exhaust aftertreatment system regeneration status; checking....120
Diesel particulate filter; replacing ....122
AdBlue®_DEF pump unit filter; replacing....133
AdBlue®_DEF tank breather filter; replacing....136
Engine air cleaner system integrity; checking....138
Engine air cleaner primary filter; cleaning....139
Engine air cleaner primary filter; replacing....142
Engine air cleaner secondary filter; replacing....145
Engine pre cleaner cyclone type; cleaning....148
Coolant level; checking....150
Coolant; changing....151
Coolant mixture; checking....154
Cooling system integrity; checking....156
Battery system integrity; checking....158
Emergency stop switch; testing....160
Planetary drive oil level; checking_{30-24}....162
Planetary drive oil level; checking_{30-12}....164
Planetary drive oil; changing_{29-53}....166
Planetary drive oil; changing_{29-41}....168
Axle oil; changing_{29-22}....171
Axle oil; changing_{29-10}....174
Axle hub oil; changing....176
Axle breather filter; cleaning....178
Parking brake function; checking....180
Articulation pin torque; checking....182
Oscillation pin torque; checking....184
Tyre wear and air pressure; checking....187
Wheel nuts torque; checking....189
Drum shock mounts; checking....190
Drum eccentric oil level; checking....193
Drum eccentric oil; changing....195
Drum carrier oil level; checking....197
Drum carrier oil; changing....199
Drum carrier breather; cleaning....201
Cab prefilter; cleaning....203
Cab prefilter; replacing....205
Cab main filter; cleaning....207
Cab main filter; replacing....210
Hydraulic oil level; checking....213
Hydraulic oil; changing....214
Hydraulic oil filters; replacing....216
Hydraulic oil tank breather filter; replacing....218
Levelling blade hydraulic oil filter; replacing....219
Towing a disabled machine....221
19 - GENERAL....232
Service position....233
Safety concerns everybody!....235
General....239
A few simple safety rules....244
Safety when handling the machine....248
Before service; read....252
Before operating....256
Electrical system....260
Checklist after a fire or heat exposure....265
Some simple rules regarding tyre handling....268
Safety when handling oil and fuel....270
Safety when lifting and supporting complete machine....273
Safety when working with batteries....275
Charging batteries....278
Cleanliness....282
Environment....286
Environmental handling for the future....291
Health hazards with paint; plastics and rubber....295
Decontamination....299
2 - ENGINE WITH MOUNTING AND EQUIPMENT....303
20 - GENERAL....304
Engine; description_{14-20}....305
Engine; description_{08-32}....312
Engine; description_{08-18}....318
Tech Tool; operations ....320
Engine control module (ECM); replacing pre-programmed_{07-42}....322
Engine control module (ECM); replacing pre-programmed_{07-30}....325
Engine control module (ECM); replacing non-programmed_{07-11}....329
Engine control module (ECM); replacing non-programmed_{06-59}....332
Engine; reference values....336
Engine belt; removing_{06-21}....338
Engine belt; removing_{06-09}....340
Engine belt; installing_{05-50}....342
Engine belt; installing_{05-39}....344
21 - ENGINE....346
Engine; specifications....347
Engine rotation speed sensor (crankshaft); replacing_{04-22}....349
Engine rotation speed sensor (crankshaft); replacing_{04-09}....352
Engine rotation speed sensor (camshaft); replacing....355
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope....357
Engine; tightening torques_{02-48}....365
Engine; tightening torques_{02-36}....366
Engine; tightening torques_{02-24}....367
Cylinder compression; testing....376
Crankcase ventilation; description....379
Valves; adjusting_{59-50}....383
Valves; adjusting_{55-27}....387
Valve cover; removing....393
Valve cover; installing....396
22 - LUBRICATING SYSTEM....399
Lubrication system; description_{43-14}....400
Lubrication system; description_{42-57}....406
Lubrication system; specifications....408
Lubrication system; component locations_{42-15}....410
Lubrication system; component locations_{42-03}....412
Lubrication system; tightening torques....414
Lubrication oil pressure; checking with pressure gauge_{40-54}....418
Lubrication oil pressure; checking with pressure gauge_{40-41}....422
23 - FUEL SYSTEM....426
Fuel system; description_{40-12}....427
Fuel system; description_{27-00}....435
Fuel system; tightening torques....437
Fuel system; tightening torques_{26-27}....441
Carbon dioxide in fuel system; checking....448
Fuel system; component locations_{48-29}....454
Fuel system; component locations_{48-17}....457
Fuel pump; replacing_{47-30}....459
Fuel pump; replacing_{47-17}....462
Fuel system; bleeding....464
Injectors; replacing_{45-52}....466
Injectors; replacing_{45-37}....472
Fuel rail; replacing_{45-18}....474
Fuel rail; replacing_{45-06}....477
Fuel rail pressure sensor; replacing....481
High pressure fuel pump; replacing_{44-29}....483
High pressure fuel pump; replacing_{44-08}....486
High pressure fuel pipes; replacing_{43-48}....489
High pressure fuel pipes; replacing_{43-36}....491
Fuel control valve (FCV); replacing_{43-17}....495
Fuel control valve (FCV); replacing_{43-04}....501
Pressure relief valve (PRV); replacing....506
25 - INLET & EXHAUST SYSTEM....508
Inlet and exhaust system; description_{41-05}....510
Inlet and exhaust system; description_{40-42}....517
Inlet and exhaust system; specification....518
Inlet and exhaust system; component locations_{40-10}....520
Inlet and exhaust system; component locations_{39-58}....523
Inlet and exhaust system; tightening torques_{39-39}....525
Inlet and exhaust system; tightening torques_{39-26}....527
Inlet and exhaust system; tightening torques_{38-57}....534
Exhaust pipe flexible tube; replacing....536
Exhaust aftertreatment system; description....541
Exhaust aftertreatment system; component locations....558
Regeneration process; description....561
AdBlue®_DEF dosing injector; replacing....570
AdBlue®_DEF mixing tube; replacing....573
AdBlue®_DEF tank; replacing....582
AdBlue®_DEF; draining....587
Coolant valve; replacing....589
SCR (Selective catalytic reduction) muffler; replacing....592
AdBlue®_DEF quality; checking....595
SCR (Selective catalytic reduction) dosing system; checking....598
AdBlue®_DEF pump unit diagnostics; description....602
Diesel particulate filter; replacing....607
ACM (Aftertreatment control module) non-programmed; replacing....608
ACM (Aftertreatment control module) pre-programmed; replacing....610
Inlet throttle; replacing....612
DOC (Diesel oxidation catalyst); replacing....615
Muffler; replacing....626
AdBlue®_DEF pump unit; replacing....632
AdBlue®_DEF tank armature; replacing....637
AdBlue®_DEF tank armature; cleaning....642
AdBlue®_DEF tank armature suction filter; replacing....645
AdBlue®_DEF....647
Crystallization of AdBlue®_DEF; checking....655
AdBlue®_DEF pump unit; flushing....662
AdBlue®_DEF pump unit; inlet nipple; replacing....665
Regeneration log; checking....668
Exhaust aftertreatment system; regenerating....681
Turbocharger; replacing_{27-53}....683
Turbocharger; replacing_{27-41}....688
Wastegate; checking....694
Air cleaner; removing....696
Air cleaner; installing....698
Preheating coil; replacing_{26-12}....700
Preheating coil; replacing_{25-59}....706
26 - COOLING SYSTEM....708
Cooling system; description....709
Cooling system; specifications....714
Carbon dioxide in coolant system; checking....716
Cooling system; component locations....723
Cooling system; tightening torques_{23-47}....726
Cooling system; tightening torques_{23-34}....728
Fan control valve; specifications....730
Fan pump; specifications....731
Coolant pump; replacing_{22-21}....732
Coolant pump; replacing_{22-09}....736
Thermostat; replacing_{21-50}....740
Thermostat; replacing_{21-37}....743
Cooling fan; description....746
Fan pump; removing....751
Fan pump; installing....753
29 - MISCELLANEOUS....756
EGR (Exhaust Gas Recirculation); description....757
EGR (Exhaust Gas Recirculation); component locations....765
EGR system; tightening torques....767
EGR reed valve; replacing....770
EGR cooler; replacing....778
EGR actuator; replacing....784
EGR venturi tube; replacing....789
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....794
30 - GENERAL....795
Tech Tool; operations ....799
Software parameters; description....800
General fault diagnosis information....804
Troubleshooting strategy....807
Collection of basic data....810
Conditions when checking....814
Lead and connector checks....818
Troubleshooting tools....825
Special tools for troubleshooting....828
Tech Tool; operations....831
BB1 Communication bus; description and measuring....832
BB2 Communication bus; description and measuring....835
CAN3; description and measuring....838
CU3622 CAN; description and measuring....841
Power supply CU3622; description and measuring....843
FX1007; description and measuring....845
FX1074; description and measuring....847
FX1079; description and measuring....850
HE2501; description and measuring....852
HE2511; description and measuring....853
HE2512; description and measuring....855
HE2513; description and measuring....857
IC2; description and measuring....859
MA2301-MA2304; description and measuring_{01-19}....862
MA2301-MA2304; description and measuring_{00-32}....864
MA2517; description and measuring....866
MA2519; description and measuring....868
MA4202; description and measuring....870
MA4212; description and measuring....872
MA4228; description and measuring....873
MA4407; description and measuring....875
MA4410; description and measuring....877
MA9151; description and measuring....879
MO2503; description and measuring....880
MO2505; description and measuring....882
MO3301; description and measuring_{53-39}....885
MO3301; description and measuring_{53-14}....887
Power supply; ACM (Aftertreatment Control Module); description and measuring....889
Power supply ECM; description and measuring....891
Power supply GPMECU 1; description and measuring....893
Power supply HMICU; description and measuring....895
PWM2303; description and measuring....897
PWM9150; description and measuring....899
PWM9426; description and measuring_{49-02}....901
PWM9426; description and measuring_{48-28}....903
PWM9427; description and measuring_{47-48}....905
PWM9427; description and measuring_{47-16}....907
PWM9430; description and measuring....909
PWM9431; description and measuring....911
RE2501; description and measuring....913
RE3705; description and measuring....915
SAE J1939-1 SubNet 1; description and measuring....918
SE2203; description and measuring....921
SE2301; description and measuring....923
SE2302; description and measuring....925
SE2303; description and measuring....927
SE2309; description and measuring....929
SE2502; description and measuring....931
SE2507; description and measuring....933
SE2511; description and measuring....935
SE2513; description and measuring....936
SE2515; description and measuring....938
SE2516; description and measuring....940
SE2519; description and measuring....942
SE2521; description and measuring....944
SE2522; description and measuring....946
SE2533; description and measuring....948
SE2543; description and measuring....950
SE2544; description and measuring....952
SE2603; description and measuring....954
SE2604; description and measuring....956
SE2606; description and measuring_{29-48}....958
SE2606; description and measuring_{29-19}....960
SE2701; description and measuring....962
SE2703; description and measuring....964
SE5501; description and measuring....966
SE8701; description and measuring....968
SE8702; description and measuring....970
SE8705; description and measuring....972
SE9105; description and measuring....974
SE9426; description and measuring....976
SE9428; description and measuring....977
SE9429; description and measuring....979
SE9600; description and measuring....981
SE9601; description and measuring....984
SW5501; description and measuring....987
Multimeter 8889 0074....989
Test pins 999 0008....991
Adapter cable 999 0014_19-20....993
Adapter cable 999 0020....995
Extension cable 999 0062....997
Adapter cable 999 3893....999
Multi-pin breaker box 999 8699....1001
Template 8889 0019....1003
Harness 8889 0016....1005
Adapter cable 999 0014....1007
Adapter cable 999 0216....1009
Traction control error codes; description....1011
Vibration control error code; description....1012
32 - ALTERNATOR; CHARGE REGULATOR....1014
Alternator; description....1015
Alternator; removing_{14-57}....1018
Alternator; removing_{14-45}....1022
Alternator; installing_{14-27}....1025
Alternator; installing_{14-14}....1029
33 - STARTING SYSTEM....1032
Starting system; description....1033
Starter motor; tightening torques....1037
36 - OTHER ELECTRICAL EQUIPMENT....1040
Crimping tools....1041
Dismantling tools....1053
GPMECU; changing non-programmed ECU....1065
GPMECU; changing pre-programmed ECU....1068
HMICU non-programmed; replacing....1071
HMICU pre-programmed; replacing....1074
37 - CABLE; FUSE; RELAY....1077
Smart diagrams; description....1079
Smart diagrams; symbols and designations....1092
Components list....1101
Component list; Diodes....1109
Component list; fuses....1110
Component list; Miscellaneous....1112
Component list; motors....1114
Component list; relays....1115
Component list; sensors....1117
Component list; Solenoid valves....1119
Component list; Switches....1120
ACM; I_O list....1126
CU3622; I_O list....1129
CU8710; I_O list....1130
E-ECU; I_O list....1132
GPM-ECU; I_O list....1136
HMICU; I_O list....1140
W-ECU; I_O list....1142
Wiring diagram index....1143
Wiring diagram 1....1144
Wiring diagram 2....1147
Wiring diagram 3....1150
Wiring diagram 4....1153
Wiring diagram 5....1156
Wiring diagram 6....1159
Wiring diagram 7....1162
Wiring diagram 8....1165
Wiring diagram 9_{59-54}....1168
Wiring diagram 9_{59-41}....1171
Wiring diagram 10....1174
Wiring diagram 11....1177
Wiring diagram 12....1180
Wiring diagram 13....1183
Wiring diagram 14....1186
Wiring diagram 15....1189
Wiring diagram 16....1192
Wiring diagram 17....1195
Wiring diagram 18....1198
Wiring diagram 19_{56-19}....1201
Wiring diagram 19_{56-06}....1204
Wiring diagram 20....1207
Wiring diagram 21....1210
Wiring diagram 22....1213
Wiring diagram 23....1216
Wiring diagram 24....1219
Wiring diagram 25_{54-03}....1222
Wiring diagram 25_{53-50}....1225
Positive feed....1228
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....1229
Compact assist; functional description....1230
Volvo Co-Pilot; description....1233
Volvo Co-Pilot; component location....1235
Volvo Co-Pilot; replacing....1237
Volvo Co-Pilot SIM card; installing....1240
USB tethering....1244
Volvo Co-Pilot Android software; updating online (OtA)....1250
Volvo Co-Pilot Android software; updating offline (USB)....1252
Volvo Co-Pilot; software updating....1254
Smart Receiver; replacing....1259
GNSS Antenna; replacing....1261
Inertial measurement unit (IMU); replacing....1263
Display unit; troubleshooting....1266
39 - MISCELLANEOUS....1269
CareTrack system; description....1270
W-ECU MID 142 non-programmed; replacing....1272
W-ECU MID 142 pre-programmed; replacing....1276
CareTrack battery; replacing....1279
CareTrack antenna; replacing....1285
4 - POWER TRANSMISSION....1290
42 - TRANSMISSION; HYDRAULIC CONTROL....1291
Propulsion control cable; checking and adjusting....1292
Propulsion control lever; replacing....1294
44 - HYDROSTATIC DRIVE....1298
Propulsion system; tightening torques....1299
Hydrostatic drive system; description....1304
Propulsion pump; description....1308
Propulsion pump; specifications....1310
Axle motor; description....1311
Axle motor; specifications....1313
Drum drive motor; description....1314
Drum drive motor; specifications....1316
Traction control system; description....1317
Traction control valve; description....1320
Traction control microprocessor; description....1322
Brake_shunt valve function; description....1324
Thermal bypass valve; description....1326
Loop flushing valve; description....1328
Thermal bypass valve; specifications....1330
Propulsion planetary; removing....1331
Propulsion planetary; installing....1335
Rear axle drive motor; removing_{39-33}....1339
Rear axle drive motor; removing_{39-21}....1342
Rear axle drive motor; installing_{39-03}....1345
Rear axle drive motor; installing_{38-51}....1348
Drum drive motor speed sensor; replacing....1350
Rear axle motor speed sensor; replacing....1353
ASC (Anti-spin control) solenoid; replacing....1355
Traction control module; replacing....1357
Propulsion pump; multi function valve; replacing....1359
Charge pressure relief valve; replacing....1361
Traction control valve; replacing....1363
Propulsion pump; removing....1367
Propulsion pump; installing....1370
46 - FRONT AXLE; REAR AXLE....1374
Axle; tightening torques....1375
Axle; removing....1377
Axle; installing....1380
5 - BRAKE....1383
55 - PARKING BRAKE....1384
Parking brake; function description....1385
Axle brake; specifications....1388
Drum brake; specifications....1389
6 - STEERING....1390
60 - GENERAL....1391
Steering system; specifications....1392
Steering pump; description....1393
Steering system; description....1395
Steering valve; description....1398
Steering; tightening torques....1400
64 - STEERING....1402
Steering cylinder; replacing....1403
Steering pump; removing....1407
Steering pump; installing....1410
Steering valve; replacing....1413
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1416
71 - FRAME....1417
Frame; tightening torques....1418
Drum frame; removing....1421
Drum frame; installing....1425
Swivel; removing....1429
Swivel; installing....1433
74 - FRAME LINK....1437
Frame joint bearings; specifications....1438
Frame joint; replacing bearings....1439
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1442
Vibration motor; specifications....1444
Vibration pump; specifications....1445
Drum vibration; specifications....1447
Wheels; specifications....1448
Wheels; tightening torques....1449
Drum eccentric; description....1450
Vibration motor; description....1453
Vibration pump; description....1456
Vibration system; description_{22-05}....1459
Vibration system; description_{21-53}....1463
Vibration control microprocessor; description....1466
Drum; tightening torques....1468
Wheel; removing....1474
Wheel; installing....1476
Carrier; removing....1478
Carrier; installing....1482
Drum; removing....1486
Drum; installing....1490
Eccentric weight; removing....1494
Eccentric weight; installing....1499
Drum drive motor; replacing....1504
Drum shock mount; replacing....1507
Vibration motor; removing....1509
Vibration motor; installing....1511
Vibration pump; removing....1513
Vibration pump; installing....1517
Eccentric weight; overhauling_{16-31}....1522
Eccentric weight; overhauling_{16-19}....1526
Eccentric weight bearings; replacing....1530
Carrier bearings; replacing....1536
Drum drive assembly; removing....1539
Drum drive assembly; installing....1542
Vibration pump charge pressure relief valve; adjusting....1544
Vibration system pressure; checking....1546
Vibration control module; replacing....1550
Vibration pump charge pressure relief valve; replacing....1552
Vibration pump SCR (system check_relief) valve; replacing....1554
Smooth drum scrapers; replacing....1556
Vibration speed sensor; replacing....1558
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1560
81 - CAB; NAKED; CANOPY....1561
Cab; removing....1562
Cab; installing....1569
Operator's platform; tightening torques....1576
Operator's platform; raising....1580
Operator's platform; lowering....1583
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1586
Engine hood; manually operating....1587
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....1589
Windows; general....1590
Side window; replacing_{08-57}....1591
Windscreen; replacing_{08-37}....1600
Window pane; installing....1609
Windows; general; gluing....1613
87 - AIR CONDITIONING UNIT....1615
Climate control system; description....1616
Air conditioning; specifications....1622
Climate unit; tightening torques....1623
Climate unit; removing....1625
Climate unit; installing....1632
Fan motor; replacing....1639
Air mix door actuator; replacing....1642
Heater core; replacing....1647
Heat control valve; replacing....1649
Air conditioning performance; checking....1654
Cooling unit; leak detection....1656
Drying filter; replacing....1658
Condenser; replacing....1661
Compressor; replacing....1665
Evaporator; replacing....1671
Expansion valve; replacing....1679
Refrigerant; draining....1688
Refrigerant; filling incl vacuum pumping....1691
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1695
90 - GENERAL....1696
Explanations to hydraulic diagram....1697
Hydraulic components; cleanliness when handling....1706
Hydraulic diagram; component locations....1709
Hydraulic diagram 1_{58-00}....1714
Hydraulic diagram 1_{57-48}....1717
Hydraulic diagram 2....1720
Hydraulic diagram 3_{57-09}....1723
Hydraulic diagram 3_{56-57}....1726
Hydraulic diagram 4....1729
Hydraulic pressure; testing....1731
Hydraulic system; tightening torques....1733
Volvo Soil Compactors SD135B Repair Service Manual
