Volvo Soil Compactors SD135 Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Soil Compactors SD135, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Soil Compactors SD135 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 SD135 Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,405 pages
File Format: PDF
Language: English
TABLE OF CONTENTS
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torque; specifications_{55-40}....5
Tightening torque; specifications_{55-28}....8
Conversion tables....11
Thread locking compound; application_specifications....19
Critical mounting torques....22
Coolant; specifications....25
Hydraulic connections; tightening torques....26
07 - STANDARD TIME....33
Operation numbers for additional work....34
08 - TOOL....36
E-7021....37
88830095 Lifting tool user instructions....39
88830142 Adapter user instructions....44
88830352 Adapter user instructions....48
1 - STANDARD PARTS; SERVICE....52
16 - LUBRICANT; FUEL; OTHER FLUID....53
Recommended lubricants....54
Fuel; lubricant and filling capacities....58
17 - SERVICE....59
Scheduled maintenance....62
Arrival Inspection; according to Inspection Programme....64
Delivery Inspection; according to Inspection Programme....65
Maintenance of Stored Machines; according to Inspection Programme....66
Maintenance service; daily....67
Maintenance service; every 50 hours....68
Maintenance service; every 500 hours....70
Maintenance service; every 1000 hours....72
Maintenance service; every 2000 hours....74
Maintenance service; every 3000 hours....76
Maintenance service; every 6000 hours....77
Maintenance service; first 50 hours....78
Engine oil level; checking....79
Fuel_water separator; draining....81
Engine air cleaner system integrity; checking....82
Coolant level; checking....83
Wheel nuts torque; checking....84
Engine air cleaner primary filter; cleaning....85
Engine air cleaner primary filter; replacing....88
Engine air cleaner secondary filter; changing....91
Parking brake function; checking....94
Emergency stop switch; checking....96
Tyres; checking air pressure....97
Steering cylinder pins; greasing....99
Swivel joint (horizontal and vertical) pins; greasing....100
Axle wheel end oil level; checking....103
Axle differential and brake oil level; checking....105
Axle breathers; cleaning....107
Engine oil and filter; changing....109
Engine oil filter; replacing....110
Battery system integrity; checking....112
Hydraulic oil level; checking....114
Fuel filter; replacing....115
Water separator; replacing....117
Cooling system integrity; checking....119
Radiator and coolers; cleaning....120
Planetary drive oil level; checking....121
Ratchet jack; greasing....123
Drum carrier breather; cleaning....125
Horizontal swivel pin torque; checking....127
Vertical swivel pin torque; checking....130
Cab ventilation filters; cleaning....133
Cab prefilter; replacing....137
Engine oil; draining....139
Engine oil; filling....141
Belt condition; checking....142
Belt tensioner; checking....144
Drum eccentric oil level; checking....145
Drum eccentric oil; draining....147
Drum eccentric oil; filling....149
Drum carrier oil level; checking....151
Drum carrier oil; draining....153
Drum carrier oil; filling....155
Fuel tank breather filter; replacing....156
Hydraulic system breather filter; replacing....158
Axle wheel end oil; changing....160
Axle differential and brake oil; changing....162
Hydraulic oil filters; replacing....166
Hydraulic oil tank; draining....168
Hydraulic oil tank; filling....170
Hydraulic oil suction strainer; cleaning....172
Planetary drive oil; changing....174
Coolant mixture; checking....176
Valves; adjusting_30-29....178
Coolant; draining....183
Coolant; filling....186
Diesel particulate filter; replacing_29-28....188
Engine hood; operating_29-06....195
Fuel system; bleeding_28-45....197
Drum shock mount; replacing_28-27....199
Drum shock mounts; checking....201
Cab main filter; replacing....204
19 - GENERAL....207
Service position....208
Safety concerns everybody!....210
A few simple safety rules....214
Safety when handling the machine....218
Before service; read....222
Before operating....226
Electrical system....230
Check list after fire or heat exposure....235
Some simple rules regarding tyre handling....236
Safety when handling oil and fuel....238
Safety when lifting and supporting complete machine....241
Safety when working with batteries....243
Charging batteries....246
Cleanliness....250
Environment....254
Environmental handling for the future....259
Health hazards with paint; plastics and rubber....263
Decontamination....267
2 - ENGINE WITH MOUNTING AND EQUIPMENT....271
20 - GENERAL....272
Engine; description....273
Engine; software specifications....277
VCADS Pro; Operations....279
Component locations....281
E-ECU MID 128 pre-programmed; replacing....284
E-ECU MID 128 non-programmed; replacing....286
Engine belt; removing....288
Engine belt; installing....289
21 - ENGINE....290
Engine; specifications....291
Engine rotation speed sensor (crankshaft); replacing....292
Engine rotation speed sensor (camshaft); replacing....296
Engine; tightening torques....298
Cylinder compression; testing....300
Crankcase ventilation; description....302
Valves; adjusting....303
22 - LUBRICATING SYSTEM....308
Lubrication system; description....309
Lubrication system; specifications....313
Lubrication system; tightening torques....315
Lubrication system; component locations....316
Lubrication oil pressure; checking with pressure gauge....319
23 - FUEL SYSTEM....322
Fuel system; description....323
Fuel system; specifications....329
Fuel system; tightening torques....330
Carbon dioxide in fuel system; checking....331
Fuel system; component locations....333
Fuel; specifications....335
Feed pump pressure; checking....336
Fuel pump; replacing....338
Fuel system; bleeding....340
Fuel level sender; replacing ....342
Injectors; replacing....344
Fuel rail pressure sensor; replacing....359
Pressure relief valve (PRV); replacing....361
High pressure fuel system pressure; relieving....364
25 - INLET & EXHAUST SYSTEM....366
Inlet and exhaust system; description....367
Inlet and exhaust system; specification....371
Inlet and exhaust system; component locations....372
Inlet and exhaust system; tightening torques....374
Exhaust pipe flexible tube; replacing....376
Exhaust aftertreatment system; description....379
Exhaust Aftertreatment System; component location....391
Regeneration process; description....394
Exhaust aftertreatment system; specifications....397
Diesel particulate filter; replacing....400
Spark plug control unit; replacing....407
Glow plug; replacing....410
Fuel metering unit A; replacing....412
Fuel metering unit B; replacing....417
Air pump safety valve; replacing....430
ACM (Aftertreatment control module) non-programmed; replacing....432
ACM (Aftertreatment control module) pre-programmed; replacing....434
Spark plug; inspecting....436
Spark plug; replacing....438
Spark plug cable; replacing....440
Air pump; replacing....442
Burner function; checking....448
Burner; replacing....454
DPF (Diesel particulate filter) inlet temperature sensor; replacing....464
DOC (Diesel oxidation catalyst); replacing....466
DPF (Diesel particulate filter) outlet temperature sensor; replacing....474
Turbocharger; description....478
Turbocharger; replacing....480
Wastegate; checking....487
26 - COOLING SYSTEM....489
Cooling system; description....490
Cooling fan motor; specifications....492
Cooling system; component locations....493
Cooling system; tightening torques....496
Cooling system leakage; checking....497
Fan pump; specifications....499
Coolant pump; replacing....500
Thermostat; replacing....503
Thermostat; specifications....508
Cooling fan; description....509
Fan pump; removing....514
Fan pump; installing....516
27 - ENGINE CONTROL....519
Engine speed control switch; description....520
29 - MISCELLANEOUS....521
EGR (Exhaust Gas Recirculation); description....522
EGR (Exhaust Gas Recirculation); component locations....526
EGR system; tightening torques....528
EGR reed valve; replacing....529
EGR cooler; replacing....531
EGR valve; replacing....541
EGR actuator; replacing....545
EGR system function; checking....549
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....552
30 - GENERAL....553
Electrical system; description....556
Electronic control system; description....559
Communication with data buses....560
Software....562
Software versions and ECUs_part number; general....563
Software versions and ECUs_part number; checking....564
Data links; fault tracing with Oscilloscope....565
Electrical system; specifications....575
VCADS Pro; Description....576
Software parameters; description....578
VCADS Pro; 17034-3 - Vehicle information; test....583
General fault diagnosis information....584
Troubleshooting strategy....587
Collection of basic data....590
Conditions when checking....594
Lead and connector checks....598
Troubleshooting tools....605
Special tools for troubleshooting....608
CU2501; description and measuring....611
CU2503; description and measuring....613
FX1007; description and measuring....615
FX1031; description and measuring....618
MA2301-MA2304; description and measuring....621
MA2301-MA2306; description and measuring....623
MA2508; description and measuring....625
MA2509; description and measuring....627
MA2510; description and measuring....629
MA2512; description and measuring....634
MA4202; description and measuring_{31-54}....636
MA4202; description and measuring_{31-31}....638
MA4212; description and measuring....640
MA4228; description and measuring....642
MA4407; description and measuring....643
MA4410; description and measuring....645
MO2502; description and measuring....647
PWM2303; description and measuring....649
PWM9150; description and measuring....651
PWM9151; description and measuring....653
PWM9426; description and measuring....655
PWM9427; description and measuring....657
PWM9430; description and measuring....659
PWM9431; description and measuring....660
R3606; description and measuring....661
RE3101; description and measuring....662
RE3102; description and measuring....664
RE3301; description and measuring....666
SE2203; description and measuring....668
SE2301; description and measuring....670
SE2302; description and measuring....673
SE2303; description and measuring....675
SE2309; description and measuring....677
SE2512; description and measuring....681
SE2513; description and measuring....683
SE2516; description and measuring....685
SE2519; description and measuring....688
SE2520; description and measuring....690
SE2521; description and measuring....692
SE2522; description and measuring....694
SE2523; description and measuring....696
SE2524; description and measuring....698
SE2525; description and measuring....700
SE2526; description and measuring....702
SE2603; description and measuring....704
SE2606; description and measuring....706
SE2607; description and measuring....708
SE2701; description and measuring....710
SE2703; description and measuring....712
SE5501; description and measuring....714
SE8502; description and measuring....715
SE9105; description and measuring....717
SE9426; description and measuring....719
SE9428; description and measuring....721
SE9429; description and measuring....722
Multimeter 8889 0074....723
Test pins 999 0008....725
Adapter cable 999 0020....727
Extension cable 999 0062....729
Adapter cable 999 3893....731
Multi-pin breaker box 999 8699....733
Template 8889 0019....735
Harness 8889 0016....737
Adapter cable 999 0014....739
Adapter cable 999 0216....741
Traction control error codes; description....743
Vibration control error code; description....744
31 - BATTERY....746
Battery; specifications....747
32 - ALTERNATOR; CHARGE REGULATOR....748
Alternator; specifications....749
33 - STARTING SYSTEM....750
Starter motor; specifications....751
Grid heater; specifications....752
Starter motor; tightening torques....753
36 - OTHER ELECTRICAL EQUIPMENT....756
Connectors; overview....757
Crimping tools....766
Dismantling tools....778
Instrument control unit I-ECU; description....790
Vehicle control unit V-ECU; description....792
Engine control unit E-ECU; description....793
I-ECU MID 140 non-programmed; replacing....794
I-ECU MID 140 pre-programmed; replacing....796
V-ECU MID 187 pre-programmed; replacing....798
V-ECU MID 187 non-programmed; replacing....802
37 - CABLE; FUSE; RELAY....806
Component list; Diodes_53-54....809
Component list; Diodes_53-39....810
Component list; Diodes....811
Component list; fuses_{53-03}....812
Component list; fuses_{52-51}....814
Component list; Miscellaneous....817
Component list; motors....820
Component list; PWM valves....822
Component list; relays....824
Component list; sensors....826
Component list; Solenoid valves....830
Component list; Switches_{50-46}....833
Component list; Switches_{50-34}....836
Wiring diagram index_{50-15}....841
Wiring diagram index_{50-03}....842
Wiring diagram 1_{49-45}....844
Wiring diagram 1_{49-33}....847
Wiring diagram 2_{49-13}....850
Wiring diagram 2_{49-00}....853
Wiring diagram 3_{48-40}....855
Wiring diagram 3_{48-27}....858
Wiring diagram 4_{48-07}....861
Wiring diagram 4_{47-53}....864
Wiring diagram 5....867
Wiring diagram 6_{47-16}....870
Wiring diagram 6_{47-03}....873
Wiring diagram 7_{46-46}....875
Wiring diagram 7_{46-33}....878
Wiring diagram 8_{46-13}....881
Wiring diagram 8_{46-00}....884
Wiring diagram 9_{45-41}....887
Wiring diagram 9_{45-28}....890
Wiring diagram 10_{45-08}....893
Wiring diagram 10_{44-55}....896
Wiring diagram 11_{44-36}....899
Wiring diagram 11_{44-23}....901
Wiring diagram 12....903
Wiring diagram 13_{43-44}....906
Wiring diagram 13_{43-31}....909
Wiring diagram 14_{43-12}....911
Wiring diagram 14_{42-58}....914
Wiring diagram 15_{42-39}....917
Wiring diagram 15_{42-25}....920
Wiring diagram 16_{42-05}....923
Wiring diagram 16_{41-52}....926
Wiring diagram 17_{41-35}....929
Wiring diagram 17_{41-22}....932
Wiring diagram 18_{41-05}....935
Wiring diagram 18_{40-52}....938
Wiring diagram 19_{40-35}....941
Wiring diagram 19_{40-22}....944
Wiring diagram 20_{40-02}....947
Wiring diagram 20_{39-49}....950
Wiring diagram 21_{39-29}....953
Wiring diagram 21_{39-16}....956
Wiring diagram 22_{38-56}....959
Wiring diagram 22_{38-44}....962
Wiring diagram 23_{38-24}....965
Wiring diagram 23....968
Wiring diagram 24_{37-51}....971
Wiring diagram 24_{37-38}....974
Wiring diagram 25....976
Positive feed....979
Grounding points; frame connections....980
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....982
Fuel level sender; replacing....983
Central warning....985
4 - POWER TRANSMISSION....986
42 - TRANSMISSION; HYDRAULIC CONTROL....987
Propulsion control lever; replacing....988
44 - HYDROSTATIC DRIVE....992
Hydrostatic drive system; description....994
Propulsion pump; description....998
Propulsion pump; specifications....1000
Rear axle drive motor; description....1001
Rear axle drive motor; specifications....1003
Drum drive motor; description....1004
Drum drive motor; specifications_{31-58}....1006
Drum drive motor; specifications_{31-46}....1007
Traction control system; description_{31-30}....1008
Traction control system; description_{31-19}....1012
Traction control valve; description....1015
Traction control valve; specifications....1017
Traction control microprocessor; description....1018
Brake_shunt valve function; description....1021
Two speed travel system; description....1024
Thermal bypass valve; description....1027
Loop flushing valve; description....1029
Thermal bypass valve; specifications....1031
Propulsion planetary; removing....1032
Propulsion planetary; installing....1036
Rear axle drive motor; removing....1040
Rear axle drive motor; installing....1043
Propulsion pump charge pressure; checking....1045
Propulsion pump system pressure; checking....1047
Drum drive motor speed sensor; replacing....1050
Rear axle motor speed sensor; replacing....1053
ASC (Anti-spin control) solenoid; replacing....1055
Drive enable valve solenoid; replacing....1057
Drive enable valve; replacing....1059
Hi_low drum drive motor valve solenoid; replacing....1061
Hi_low drum drive motor valve; replacing....1063
Loop flushing valve; replacing....1065
Traction control module; replacing....1067
Propulsion pump; multi function valve; replacing....1069
Charge pressure relief valve; replacing....1071
Propulsion pump; removing....1073
Propulsion pump; installing....1076
46 - FRONT AXLE; REAR AXLE....1080
Heavy duty rear axle; description....1081
5 - BRAKE....1083
55 - PARKING BRAKE....1084
Parking brake; function description....1085
Parking brake release valve; replacing....1088
Axle brake; specifications....1090
Drum brake; specifications....1091
Brake release valve solenoid; replacing....1092
6 - STEERING....1094
60 - GENERAL....1095
Steering system; specifications....1096
Steering pump; description....1097
Steering system; description....1099
Steering valve; description....1103
Steering pump; specifications....1105
Steering orbital; specifications....1106
Steering cylinder; specifications....1107
64 - STEERING....1108
Steering cylinder; replacing....1109
Steering pump; removing....1113
Steering pump; installing....1116
Steering valve; replacing....1119
Steering pressure; checking....1123
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....1125
71 - FRAME....1126
Drum frame; removing....1127
Drum frame; installing....1131
Swivel; removing....1135
Swivel; installing....1139
74 - FRAME LINK....1143
Frame joint bearings; specifications....1144
Frame joint; replacing bearings....1145
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....1148
Vibration motor; specifications....1150
Vibration pump; specifications....1151
Drum vibration; specifications....1152
Wheels; specifications....1154
Wheels; tightening torques....1155
Drum carrier; description_{09-32}....1156
Drum carrier; description_{09-38}....1159
Drum eccentric; description....1161
Vibration motor; description....1164
Vibration pump; description....1166
Vibration system; description....1170
Vibration control microprocessor; description....1175
Wheel; removing....1177
Wheel; installing....1179
Carrier; removing....1181
Carrier; installing....1185
Drum; removing....1189
Drum; installing....1193
Eccentric weight; removing....1197
Eccentric weight; installing....1202
Drum drive motor; replacing....1207
Drum shock mount; replacing....1210
Vibration motor; removing....1212
Vibration motor; installing....1214
Vibration pump; removing....1216
Vibration pump; installing....1220
Eccentric weight; overhauling....1225
Eccentric weight bearings; replacing....1230
Carrier bearings; replacing....1237
Drum drive assembly; removing....1241
Drum drive assembly; installing....1244
Vibration pump charge pressure; checking....1246
Vibration pump charge pressure relief valve; adjusting....1248
Vibration system pressure; checking....1250
Vibration control module; replacing....1253
Vibration pump charge pressure relief valve; replacing....1255
Vibration pump SCR (system check_relief) valve; replacing....1257
Smooth drum scrapers; replacing....1259
Vibration speed sensor; replacing....1261
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....1263
81 - CAB; NAKED; CANOPY....1264
Cab; removing....1265
Cab; installing....1273
Operator's platform; raising....1281
Operator's platform; lowering....1284
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....1287
Engine hood; operating....1288
Engine hood; manually operating....1290
87 - AIR CONDITIONING UNIT....1292
Climate control system; description....1293
Air conditioning; specifications_{55-30}....1299
Air conditioning; specifications_{55-18}....1300
Climate unit; tightening torques....1301
Climate unit; removing....1303
Climate unit; installing....1310
Fan motor; replacing....1316
Air mix door actuator; replacing....1319
Heater core; replacing....1324
Heat control valve; replacing....1326
Air conditioning performance; checking....1331
Cooling unit; leak detection....1333
Drying filter; replacing....1335
Condenser; replacing....1338
Compressor; replacing....1342
Evaporator; replacing....1348
Expansion valve; replacing....1356
Refrigerant; draining....1365
Refrigerant; filling incl vacuum pumping....1368
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....1372
90 - GENERAL....1373
Explanations to hydraulic diagram....1374
Hydraulic components; cleanliness when handling....1383
Hydraulic diagram 1_{18-04}....1386
Hydraulic diagram 1_{17-49}....1387
Hydraulic diagram 2....1390
Hydraulic diagram 2 - Explanations to hydraulic diagram....1391
Hydraulic diagram 3....1394
Hydraulic diagram 3 - Explanations to hydraulic diagram....1395
Hydraulic diagram 4....1398
Hydraulic diagram 4 - Explanations to hydraulic diagram....1400
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....1401
Hydraulic return line filter; specification....1402
Hydraulic system; description....1403
Volvo Soil Compactors SD135 Service Repair Manual
