Volvo Soil Compactors SD116DX Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Soil Compactors SD116DX, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Soil Compactors SD116DX 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 SD116DX Service Manual.pdf
PRODUCT DETAILS:
Total Pages: 872 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
Cab; component locations_06-03...11
Machine identification...14
Engine; identification...16
03 - SPECIFICATIONS...17
Specifications; general...18
Tightening torque; specifications_{03-45}...19
Tightening torque; specifications_{03-23}...21
Conversion tables...24
Thread locking compound; application_specifications...32
Machine dimensions...35
Machine weight; specifications...37
Critical mounting torques...38
Battery; specifications_00-42...40
Fuel; lubricant and filling capacities...41
Cooling system; specifications...42
Air conditioning; specification...43
Engine; specifications...44
Electrical system; specifications_58-54...45
Battery; specifications_58-29...46
Hydrostatic drive; specifications...47
Hydraulic pump; specifications...48
Hydraulic motor; specifications...50
Gear reducer; specifications...51
Brakes; specifications...52
Steering system; specifications...53
Frame link_articulation; specifications...54
Drum; specifications...55
Tyre sizes and pressures specifications...56
Hydraulic connections; tightening torques...57
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...60
Travelling on public road...61
Transporting the machine ...62
07 - STANDARD TIME...65
Operation numbers for additional work...66
08 - TOOL...68
E-7001...69
1 - STANDARD PARTS; SERVICE...71
16 - LUBRICANT; FUEL; OTHER FLUID...72
Recommended lubricants...73
Environmentally safe handling...77
Lubricant recommendation...79
Oil and filtration...80
Alternative fuels...82
Coolant mixture...85
17 - SERVICE...86
Arrival Inspection; according to Inspection Programme...89
Delivery Inspection; according to Inspection Programme...90
Maintenance of Stored Machines; according to Inspection Programme...91
Warranty inspection 100 hours...92
Warranty inspection 1000 hours...94
Maintenance service; every 10 hours...96
Maintenance service; every 50 hours...97
Maintenance service; every 500 hours...99
Maintenance service; every 1000 hours...101
Maintenance service; every 2000 hours...103
Maintenance service; every 3000 hours...105
Maintenance service; first 50 hours...107
Transfer gearbox; filling and checking...109
Cleaning prior to repair...111
Cleaning engine compartment...113
Engine hood; opening_41-09...115
Precaution when working on the electrical system...118
Electric welding...119
Engine oil level; check...120
Coolant level; check...123
Lap type seat belt; checking and maintenance...125
Fuel line; water separator; check and drain...126
Parking brake performance...128
Cooling system integrity; check...131
Battery disconnect switch (main switch); check...132
Steering cylinder pins; greasing...135
Coolant; changing...137
Cooling fan; check...141
Radiator and coolers; cleaning...143
Fan belt and_or alternator belt; checking and adjusting tension...145
Belt tension; checking...147
Axles; checking oil level...148
Axle hubs; checking oil level...150
Transfer gearbox; changing oil...152
Drum drive (torque hub); checking oil level...154
Carrier seal; greasing...156
Drum; checking...157
Drum shock mounts; checking...159
Drum eccentric; checking oil level...161
Drum carrier; checking oil level...163
Scraper; adjusting...166
Lamp (indicator light); checking...168
Ratchet jack; greasing...169
Swivel joint (horizontal and vertical) pins; greasing...171
Articulation (Vertical swivel pin); torque...174
Oscillation (Horizontal swivel pin); torque...176
Wheel nuts; check torque...178
Hydraulic system; checking oil level...180
Hydraulic oil filter; changing...182
Hydraulic oil tank; changing oil and filter...184
Hydraulic tank breather filter; clean...186
Hydraulic oil suction strainer; cleaning...188
Engine; air cleaner maintenance...191
Air cleaner primary filter; clean...193
Battery; maintenance...198
Axle breather; cleaning...201
Carrier breather; cleaning...203
Engine oil and filter; changing...205
Air cleaner; primary filter replacing...208
Air cleaner; secondary filter replacing...210
Fuel filters; replacing...213
Rear axle oil; changing...215
Axle hubs; changing oil...218
Drum drive (torque hub); changing oil...221
Drum carrier; changing oil...224
Drum eccentric; changing oil...227
Tyres; wear and air pressure; checking...230
Hydraulic oil tank; filling...232
Fuel system; bleeding...234
Towing a disabled machine...236
Starting with booster batteries...237
Parking brake; manually releasing...239
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump ...240
19 - GENERAL...242
Safety concerns everybody!_{11-34}...243
Safety concerns everybody!_{11-09}...247
Safety when handling the machine...249
Safe operation of the machine...252
Stopping...256
Safety when servicing...257
Service position 1...260
Fire prevention measures...264
Health hazards with paint; plastics and rubber...267
Check list after fire or heat exposure...269
Some simple rules regarding tyre handling...271
Safety when lifting and supporting complete machine...273
Transporting the machine...277
Safety when working on the electrical system...280
Safety when working with air conditioning refrigerant...282
Safety when working on hydraulic systems...285
Environmental handling for the future...287
Environmental requirements...289
Waste handling...290
Environmentally safe handling...291
Environmentally hazardous fluids...294
Working in environmentally contaminated areas...295
Handling hazardous materials...296
Decontamination...299
2 - ENGINE WITH MOUNTING AND EQUIPMENT...301
20 - GENERAL...302
Engine; description...303
Engine; symptom troubleshooting...304
Engine difficult to start...306
Heavy exhaust smoke development...307
Engine overheated...308
WARNING Low Engine Oil Pressure...309
21 - ENGINE...310
Engine; removing...311
Engine; installing...316
Valves; adjusting...321
Engine mounting; front; replacing...322
Engine mounting rear; changing...323
23 - FUEL SYSTEM...325
Fuel tank; description...326
Fuel tank; replacing_{53-00}...329
Fuel tank; replacing_{52-35}...332
25 - INLET & EXHAUST SYSTEM...335
Silencer; replacing...336
Exhaust pipe; changing pipe between silencer and turbocharger_51-07...338
Exhaust pipe; changing pipe between silencer and turbocharger...341
Air cleaner; removing...344
Air cleaner; installing...346
Air cleaner; description...348
Charge air cooler; description...351
Charge air cooler; removing...353
Charge air cooler; installing...356
Charge air cooler connection (hose; tube); replacing...358
26 - COOLING SYSTEM...360
Cooling system; description...361
Radiator; removing...362
Radiator; installing...366
Fan shroud; replacing...370
Cooling fan; replacing...372
Fan belt and_or alternator belt; replacing...374
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...378
30 - GENERAL...379
Electrical system; component overview_{37-14}...380
Electrical system; component overview_{36-43}...382
Electrical system; component overview_{36-18}...385
Electrical system; component overview_{35-54}...388
Electrical system; component overview_{35-29}...391
Electrical system; specifications...393
Troubleshooting; general...394
Engine does not start...396
INFO Low Voltage...397
Electrical troubleshooting...398
Troubleshooting; electrical control box...400
Variable vibration control...403
Traction control...406
31 - BATTERY...410
Battery; specifications...411
Batteries; replacing...412
32 - ALTERNATOR; CHARGE REGULATOR...415
Alternator; description...416
Alternator; replacing incl function checking...417
33 - STARTING SYSTEM...420
Starter motor; description...421
Starter motor; replacing...422
Starter switch (engine start switch); replacing...424
36 - OTHER ELECTRICAL EQUIPMENT...427
Reverse alarm; replacing...428
Windscreen wiper front motor; replacing...430
Windscreen wiper rear; replacing motor...433
37 - CABLE; FUSE; RELAY...436
Wiring diagram 1 Main diagram - Image...437
Wiring diagram 2 - Image...438
Wiring diagram 3 - Image...439
Wiring diagram 4 - Image...440
Wiring diagram 5 - Image...441
Colour codes...442
Wiring diagram index...444
Wiring diagram 1 Main diagram...445
Wiring diagram 2...448
Wiring diagram 3...451
Wiring diagram 4...454
Wiring diagram 5...457
Cable; Battery isolation switch...460
Component list; fuses...462
Component list; relays...464
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...466
Instruments and controls; overview...467
Control unit; description...470
Engine oil pressure sensor; replacing_{16-10}...472
Engine oil pressure sensor; replacing_{15-48}...474
Hydraulic oil temperature sensor; replacing...476
Fuel level sender; replacing...478
4 - POWER TRANSMISSION...480
40 - GENERAL...481
Power Transmission; Propulsion...482
Power train; related components...486
Travel hydraulics; troubleshooting...488
42 - TRANSMISSION; HYDRAULIC CONTROL...490
Two speed valve and solenoid; description...491
Two speed valve solenoid and cartridge; replacing...493
Pump de-stroke valve and solenoid; description...495
Pump de-stroke valve solenoid and cartridge; replacing...497
44 - HYDROSTATIC DRIVE...499
Hydrostatic controller; removing...500
Hydrostatic controller; installing...504
Rear axle drive motor; description...509
Drum drive motor; description...512
Hydraulic hose routing and fitting orientation diagrams...515
Travel motor; replacing...518
Rear axle motor speed sensor; replacing...521
Drive motor; removing...523
Drive motor; installing...526
Drum drive motor speed sensor; replacing...530
Thermal bypass valve; description...532
Thermal bypass valve; replacing...534
Hydrostatic pump; description...536
Loop flushing valve; description...539
Loop flushing valve; replacing...542
Loop flushing valve cartridge; replacing...544
Hydrostatic pump; removing_{58-53}...546
Hydrostatic pump; removing_{58-29}...550
Hydrostatic pump; installing...554
Pump coupling; removing...557
Pump coupling; installing...559
Traction control valve; description...561
Traction valve; solenoid and cartridge; replacing...564
46 - FRONT AXLE; REAR AXLE...567
Rear axle; description...568
Axle; removing...570
Axle; installing...573
5 - BRAKE...576
52 - HYDRAULIC BRAKE SYSTEM...577
Hydraulic brake system; description...578
55 - PARKING BRAKE...579
Parking brake; description...580
Multi function brake valve solenoid and cartridge; replacing...581
Parking brake pressure switch; replacing...583
6 - STEERING...585
64 - STEERING...586
Steering system; description...587
Steering system; component location...589
Steering system; symptom troubleshooting...591
Adjustable steering column; replacing...593
Steering control unit; removing...597
Steering control unit; installing...600
Steering pump; removing...602
Steering pump; installing...604
Steering cylinder; removing...606
Steering cylinder; installing...610
Steering control unit; description and operation...614
Steering pressure; checking and adjusting...616
Steering pump; description...618
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...621
71 - FRAME...622
Frame; description...623
74 - FRAME LINK...625
Frame joint; Replacing the front pivot bearing with machine separated...626
Frame joint; replacing the rear pivot bearing with machine separated...641
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...648
Wheels; tightening torques...649
Drum eccentric; description...650
Vibration motor; description...653
Vibration pump; description...655
Vibration hydraulic circuit; description...657
Vibration system; component location...659
Wheel; removing and fitting one...661
Drum; description...664
Drum; removing...667
Drum; installing_{40-42}...673
Drum; installing_{40-17}...678
Eccentric weight; removing...683
Eccentric weight; installing...686
Drum shock mount; replacing...688
Vibration motor; removing...690
Vibration motor; installing...692
Vibration pump; removing...695
Vibration pump; installing...697
Eccentric weight; overhauling...699
Eccentric shaft coupling; replacing...701
Eccentric weight bearings; replacing...703
Torque hub; removing...705
Torque hub; installing...708
Carrier bearings; replacing_{34-08}...710
Carrier bearings; replacing_{33-44}...714
Drum bolt-on shell option; installing...718
Smooth drum scrapers; replacing...723
Padfoot drum scrapers; replacing...725
Vibration system; troubleshooting...727
Vibration speed sensor; replacing...729
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...731
81 - CAB; NAKED; CANOPY...732
Cab; component locations...733
Operator's protective structure; description...736
Operator's platform; raising...739
Operator's platform; lowering...743
Viscous cab suspension; changing all units...748
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...754
Engine hood; opening...755
Engine hood; removing...758
Engine hood; installing...761
Engine hood; changing spring...763
85 - CAB INTERIOR; UPHOLSTERY...766
Operator's seat; removing...767
Operator's seat; installing...769
87 - AIR CONDITIONING UNIT...771
Climate control system; description...772
Cooler and Heater assembly; removing...773
Cooler and Heater assembly; installing...777
Cab filter; replacing...781
Fan motor; replacing...783
Heater core; replacing...786
Heat control valve; replacing...790
Heater unit relays; replacing...793
Compressor; replacing incl draining and filling...795
Compressor; replacing magnetic clutch (compressor removed)...798
Condenser; replacing incl draining and filling...801
Receiver; replacing incl draining and filling...804
Switch; replacing...806
Evaporator; replacing incl draining and filling...808
Thermostat; replacing...812
HVAC control switch; replacing_{17-01}...817
HVAC control switch; replacing_{16-40}...819
88 - INTERIOR EQUIPMENT...821
Seat safety belt; replacing...822
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...824
90 - GENERAL...825
Hydraulic diagram; with option components - Image...826
Hydraulic main diagram (Standard machine) - Image...827
Explanations to hydraulic diagram...828
Hydraulic diagram components list; standard...835
Hydraulic diagram components list; with option...837
Hydraulic main diagram (Standard machine)...839
Hydraulic diagram; with option components...843
Oil and filtration...847
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...849
Working hydraulic system; description...850
Hydraulic oil tank; description...854
Hydraulic oil tank; changing oil and filter incl.cleaning tank...857
Hydraulic oil tank; removing...859
Hydraulic oil tank; installing...861
Hydraulic oil tank; vacuum-pumping; connecting and disconnecting pump...863
Hydraulic oil cooler; description...865
Hydraulic oil cooler; removing...867
Hydraulic oil cooler; installing...870
Volvo Soil Compactors SD116DX Repair Service Manual
