Volvo Soil Compactors SD200, SD200DX Service Repair Manual
Complete repair service manual with Eletrical Wiring Diagrams for Volvo Soil Compactors SD200, SD200DX, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Soil Compactors SD200, SD200DX 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.
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
TABLE OF CONTENTS
0 - Foreword...2
0 - GENERAL...3
03 - SPECIFICATIONS...4
Critical mounting torques_{33-37}...5
Tightening torque; specifications_{33-25}...7
Tightening torque; specifications_{33-14}...10
Conversion tables...13
Thread locking compound; application_specifications...21
Battery; specifications_32-24...24
Hydraulic connections; tightening torques_{32-05}...25
Hydraulic connections; tightening torques_{31-51}...28
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...35
Travelling on public road...36
Transporting the machine ...37
07 - STANDARD TIME...40
Operation numbers for additional work...41
08 - TOOL...43
E-7001...44
1 - STANDARD PARTS; SERVICE...46
16 - LUBRICANT; FUEL; OTHER FLUID...47
Recommended lubricants...48
Lubricant recommendation...52
Oil and filtration_27-41...53
Fuel; lubricant and filling capacities...54
Environmentally safe handling ...55
17 - SERVICE...57
Arrival Inspection; according to Inspection Programme...60
Delivery Inspection; according to Inspection Programme...61
Maintenance of Stored Machines; according to Inspection Programme...62
Maintenance service; every 10 hours...63
Maintenance service; every 50 hours...64
Maintenance service; every 500 hours...66
Maintenance service; every 1000 hours...68
Maintenance service; every 2000 hours...70
Maintenance service; every 3000 hours...72
Maintenance service; first 50 hours...74
Transfer gearbox; filling and checking...76
Cleaning prior to repair...78
Cleaning engine compartment...80
Engine hood; opening ...81
Precaution when working on the electrical system...84
Electric welding...85
Engine oil level; check...86
Coolant level; check...89
Lap type seat belt; checking and maintenance...91
Fuel line; water separator; check and drain...92
Parking brake performance...94
Cooling system integrity; check...97
Battery disconnect switch (main switch); check...98
Steering cylinder pins; greasing...101
Coolant; changing...103
Cooling fan; check...107
Radiator and coolers; cleaning...109
Fan belt and_or alternator belt; checking and adjusting tension...111
Belt tension; checking...113
Axles; checking oil level...114
Axle hubs; checking oil level...116
Transfer gearbox; changing oil...118
Drum drive (torque hub); checking oil level...120
Carrier seal; greasing...122
Drum; checking...123
Drum eccentric; checking oil level...125
Drum carrier; checking oil level...127
Scraper; adjusting...130
Lamp (indicator light); checking...132
Ratchet jack; greasing...133
Swivel joint (horizontal and vertical) pins; greasing...135
Articulation (Vertical swivel pin); torque...138
Oscillation (Horizontal swivel pin); torque...140
Wheel nuts; check torque...142
Hydraulic system; checking oil level...144
Hydraulic oil filter; changing...146
Hydraulic oil tank; changing oil and filter...148
Hydraulic tank breather filter; clean...150
Hydraulic oil suction strainer; cleaning...152
Engine; air cleaner maintenance...155
Air cleaner primary filter; clean...157
Battery; maintenance...162
Axle breather; cleaning...165
Carrier breather; cleaning...167
Engine oil and filter; changing...169
Air cleaner; primary filter replacing...172
Air cleaner; secondary filter replacing...174
Fuel filters; replacing...177
Rear axle oil; changing...179
Axle hubs; changing oil...182
Drum drive (torque hub); changing oil...185
Drum carrier; changing oil...188
Drum eccentric; changing oil...191
Tyres; wear and air pressure; checking...194
Hydraulic oil tank; filling...196
Fuel system; bleeding...198
Drum shock mounts; checking...200
Towing a disabled machine...203
Starting with booster batteries...204
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...206
19 - GENERAL...208
Safety when servicing...210
Service position...213
Safety concerns everybody!_{04-01}...215
Safety concerns everybody!_{03-47}...217
Safety concerns everybody!_{03-31}...221
General...225
A few simple safety rules...230
Safety when handling the machine_{02-31}...234
Safety when handling the machine_{02-18}...237
Before service; read...241
Before operating...245
Safe operation of the machine...249
Stopping...253
Transporting the machine...254
Electrical system...257
Fire prevention measures...262
Check list after fire or heat exposure_{59-46}...265
Checklist after a fire or heat exposure_{59-34}...267
Some simple rules regarding tyre handling...270
Safety when working on the electrical system...272
Safety when handling oil and fuel...274
Safety when lifting and supporting the machine...277
Safety when working on hydraulic systems...280
Safety when working with air conditioning refrigerant...282
Safety when working with batteries...284
Charging batteries...287
Cleanliness...291
Environment...295
Environmental handling for the future...300
Environmental requirements...301
Environmentally safe handling...302
Environmentally hazardous fluids...305
Health hazards with paint; plastics and rubber ...306
Handling hazardous materials...310
Working in environmentally contaminated areas...313
Decontamination_{54-01}...314
Decontamination_{53-49}...316
Waste handling...320
Health hazards with paint; plastics and rubber...322
2 - ENGINE WITH MOUNTING AND EQUIPMENT...324
20 - GENERAL...325
Engine; description...326
Engine; symptom troubleshooting...327
Engine does not start_51-47...329
Engine difficult to start...330
Heavy exhaust smoke development...331
Engine overheated...332
WARNING Low Engine Oil Pressure...333
21 - ENGINE...334
Valves; adjusting...335
23 - FUEL SYSTEM...336
Fuel tank; description...337
Fuel tank; replacing...340
25 - INLET & EXHAUST SYSTEM...343
Air cleaner; removing...344
Air cleaner; installing...346
Air cleaner; description...348
Charge air cooler connection (hose; tube); replacing...351
Charge air cooler; description...353
26 - COOLING SYSTEM...355
Cooling system; description...356
Cooling fan; replacing...357
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...359
30 - GENERAL...360
Electrical system; component overview_{042-21}...361
Electrical system; component overview_{042-04}...363
Electrical system; component overview_{041-52}...366
Electrical system; component overview_{041-39}...369
Electrical system; specifications...372
General fault diagnosis information...373
Troubleshooting strategy...376
Collection of basic data...379
Conditions when checking...383
Lead and connector checks...387
Troubleshooting tools...394
Special tools for troubleshooting...397
Engine does not start...400
INFO Low Voltage...401
Electrical troubleshooting...402
Troubleshooting; electrical control box...404
Variable vibration control...407
Traction control...410
Battery; specifications ...414
31 - BATTERY...415
Battery; specifications...416
Batteries; replacing...417
33 - STARTING SYSTEM...419
Starter motor; description...420
Starter motor; replacing...421
Reverse alarm; replacing...423
37 - CABLE; FUSE; RELAY...425
Wiring diagram 5 - Image...426
Wiring diagram 4 - Image...427
Wiring diagram 3 - Image...428
Wiring diagram 2 - Image...429
Wiring diagram 1 - Image...430
Wiring diagram index...431
Wiring diagram 001...432
Wiring diagram 002...434
Wiring diagram 003...437
Wiring diagram 004...439
Wiring diagram 005...441
Cable; Battery isolation switch...443
Component list; fuses...445
Component list; relays...447
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...449
Instruments and controls; overview...450
Control unit; description...453
Engine oil pressure sensor; replacing_{028-12}...455
Engine oil pressure sensor; replacing_{028-00}...457
Hydraulic oil temperature sensor; replacing...459
Fuel level sender; replacing...461
4 - POWER TRANSMISSION...463
40 - GENERAL...464
Power Transmission; Propulsion...465
Power train; related components...469
Travel hydraulics; troubleshooting...471
42 - TRANSMISSION; HYDRAULIC CONTROL...473
Two speed valve and solenoid; description...474
Two speed valve solenoid and cartridge; replacing...476
Pump de-stroke valve and solenoid; description...478
Pump de-stroke valve solenoid and cartridge; replacing...480
44 - HYDROSTATIC DRIVE...482
Hydrostatic controller; removing...483
Hydrostatic controller; installing...487
Travel motor; replacing...492
Rear axle motor speed sensor; replacing...495
Drum drive motor speed sensor; replacing...497
Thermal bypass valve; description...499
Thermal bypass valve; replacing...501
Traction control valve; description...503
Traction valve; solenoid and cartridge; replacing...506
Hydrostatic pump; description...509
Loop flushing valve; description...512
Loop flushing valve; replacing...515
Loop flushing valve cartridge; replacing...517
Pump coupling; removing...519
Pump coupling; installing...521
5 - BRAKE...523
52 - HYDRAULIC BRAKE SYSTEM...524
Hydraulic brake system; description...525
55 - PARKING BRAKE...526
Parking brake; description...527
Multi function brake valve solenoid and cartridge; replacing...528
Parking brake pressure switch; replacing...530
6 - STEERING...532
64 - STEERING...533
Steering system; description...534
Steering system; component location...536
Steering system; symptom troubleshooting...538
Steering pump; removing...540
Steering pump; installing...542
Steering cylinder; removing...544
Steering cylinder; installing...548
Steering control unit; description and operation...551
Steering pump; description...553
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...556
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...557
Drum eccentric; description...558
Vibration pump; description...561
Vibration hydraulic circuit; description...563
Vibration system; component location...565
Drum; description...567
Drum shock mount; replacing...570
Drum bolt-on shell option; installing...572
Smooth drum scrapers; replacing...577
Padfoot drum scrapers; replacing...579
Vibration system; troubleshooting...581
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...583
81 - CAB; NAKED; CANOPY...584
Cab; component locations...585
Operator's protective structure; description...588
Operator's platform; raising...591
Operator's platform; lowering...595
Viscous cab suspension; changing all units...600
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...606
Engine hood; opening...607
Engine hood; removing...610
Engine hood; installing...612
85 - CAB INTERIOR; UPHOLSTERY...614
Operator's seat; removing...615
Operator's seat; installing...617
88 - INTERIOR EQUIPMENT...619
Climate control system; description...620
Cooler and Heater assembly; removing...621
Cooler and Heater assembly; installing...625
Cab filter; replacing...629
Fan motor; replacing...631
Heater core; replacing...634
Heater unit relays; replacing...638
Compressor; replacing incl draining and filling...640
Compressor; replacing magnetic clutch (compressor removed)...643
Condenser; replacing incl draining and filling...646
Receiver; replacing incl draining and filling...649
Switch; replacing...651
Evaporator; replacing incl draining and filling...653
Thermostat; replacing...657
HVAC control switch; replacing_{055-24}...662
HVAC control switch; replacing_{055-12}...664
Seat belt; replacing...666
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...668
90 - GENERAL...669
Hydraulic diagram 1 - Image...670
Explanations to hydraulic diagram...671
Hydraulic components; cleanliness when handling...678
Hydraulic diagram 001...681
Oil and filtration...683
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...684
Hydraulic oil cooler; description...685
Hydraulic oil cooler; removing...687
Hydraulic oil cooler; installing...690
Hydraulic oil tank; changing oil and filter incl.cleaning tank...693
Hydraulic oil tank; removing...695
Hydraulic oil tank; installing...697
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...699
Volvo Soil Compactors SD200, SD200DX Service Repair Manual
