Volvo DD120 Drum Compactor Service and Repair Manual PDF

Volvo DD120 Drum Compactor Service and Repair Manual PDF

Size: 102.03 MB
Language: English
Make: Volvo
Machine: Drum Compactor
Document: Service Repair Manual, Wiring Diagram, Hydraulic Diagram
Model: Volvo DD120
Page: 525 Pages

Detail Contents:
Specifications

• Alternative fuels
  Battery, specifications
  Brake system, specifications
  Critical mounting torques
  Drum, specifications
  Electrical system, specifications
  Engine, specifications
  Fuels, lubricants and filling capacities (litres)
  Hydraulic connections, tightening torques
  Hydraulic connections, tightening torques2
  Hydraulic motor, specifications
  Hydraulic pump, specifications
  Location of components
  Lubrication and oil system, general specifications
  Machine dimensions
  Machine weight, specifications
  Power transmission, specifications
  Recommended lubricants
  Specifications, general
  Steering system, specifications
  Tightening torque, specifications

Safety

• A few simple safety rules
  Before operating
  Before service, read
  Charging batteries
  Check list after fire or heat exposure
  Checklist after a fire or heat exposure
  Cleanliness
  Decontamination
  Electrical system
  Environment
  Environmental handling for the future
  Environmentally safe handling
  Fire prevention measures
  General
  Handling hazardous materials
  Health hazards with paint, plastics and rubber 2
  Health hazards with paint, plastics and rubber
  Safe operation of the machine
  Safety concerns everybody!
  Safety when handling oil and fuel
  Safety when handling the machine 2
  Safety when handling the machine
  Safety when lifting and supporting complete machine
  Safety when lifting and supporting the machine
  Safety when servicing
  Safety when working with batteries
  Stopping
  Towing a disabled machine
  Travelling on public road

Service Bulletins

• Biodiesel fuel for Volvo CE
  Check method on engine oil consumption
  Fuel sampling, method
  Hydraulic oil dye
  Lubricant specifications and service interval changes
  New fastener assortment
  New Nomenclature for DD and SD compactors
  New Product Introduction
  New TechTool VCADS Pro interface
  Portable refillable O-ring kits
  Preservation
  Reports
  Volvo Product incident accident report & Interview Form

Descriptions

• After market engine, transfer of components
  Air cleaner, description
  Alternator, description
  Backup alarm
  Cable; Battery isolation switch
  Charge air cooler, description
  Component list, fuses
  Conversion tables
  Cooling system, description
  Description, complete machine
  Drum drive motor, description
  Drum eccentric, description
  Drum, description
  Electrical troubleshooting
  Engine difficult to start
  Engine does not start
  Engine overheated
  Engine, description
  Environmentally safe handling
  Fault code 1-1-3 – Sensor voltage #1 circuit
  Fault code 1-2-2 – Machine type input circuit
  Fault code 1-2-3 – Machine model input circuit
  Fault code 1-2-4 and 1-2-5 – System status lamp circuit
  Fault code 2-1-1 and 2-1-2 – Fuel solenoid release circuit
  Fault code 2-1-3 – Fuel solenoid release circuit
  Fault code 2-3-5 – Park brake command switch circuit
  Fault code 2-4-1 – Engine running input circuit
  Fault code 3-1-1 – Eccentric drum direction switch circuit
  Fault code 3-1-2 – Eccentric drum select switch circuit
  Fault code 3-1-3 – Impact spacing auto threshold circuit
  Fault code 3-1-4 – Front VIB FWD CW solenoid circuit
  Fault Code 3-1-5 – Front VIB FWD CW Solenoid Circuit
  Fault code 3-2-1 – Front VIB REV CCW solenoid circuit
  Fault code 3-2-2 – Front VIB REV CCW solenoid circuit
  Fault code 3-2-3 – Rear VIB FWD CW solenoid circuit
  Fault code 3-2-4 – Rear VIB FWD CW solenoid circuit
  Fault code 3-2-5 – Rear VIB REV CCW solenoid circuit
  Fault code 3-3-1 – Rear VIB REV CCW solenoid circuit
  Fault code 3-3-3 – Troubleshooting circuit
  Fault code 3-4-2 – Front eccentric VPM sensor circuit
  Fault code 3-4-3 – Front eccentric VPM and drum speed sensors circuit
  Fault codes 1-1-1 and 1-1-2 – System voltage circuit
  Fault codes 1-1-4 – Sensor voltage #1 circuit
  Fault codes 1-1-5 and 1-2-1 – Sensor voltage #2 circuit
  Fault codes 2-1-4 and 2-1-5 – High throttle hold circuit
  Fault codes 2-2-1 and 2-2-2 – Drive enable circuit
  Fault codes 2-2-3 and 2-2-4 – High throttle pull circuit
  Fault codes 2-2-5 and 2-3-1 – Park brake release circuit
  Fault codes 2-3-2 and 2-3-3 – Operator absent circuit
  Fault codes 2-3-4 – Park brake test circuit
  Fault codes 3-3-2 and 3-3-4 – Vibration ON lamp circuit
  Fault codes 3-3-5 and 3-4-1 – Impact spacing meter circuit
  Frame, description
  Fuel tank, description
  Heavy exhaust smoke development
  Hydraulic brake system, description
  Hydraulic hose schematic
  Hydraulic oil cooler, description
  Hydraulic oil tank, description
  Hydraulic oil, specifications 2
  Hydraulic oil, specifications
  Hydraulic system, startup procedure
  Hydrostatic pump, description
  Infrared temperature installation
  Instruments and controls, overview
  Loop flushing valve, description
  Low engine oil pressure
  Low voltage
  Lubricant recommendation
  Machine identification
  Multi-function brake valve, description 2
  Multi-function brake valve, description
  Operator’s protective structure, description
  Power train, troubleshooting
  Power Transmission, Propulsion
  Pump de-stroke valve and solenoid, description
  Safety when working on hydraulic system
  Safety when working on the electrical system
  Service position
  Smart functions, description
  Starter motor, description
  Starting with booster batteries
  Steering system, description
  Steering system, troubleshooting
  Thread locking compound, application
  Towing procedures
  Transporting the machine
  Troubleshooting, general
  Vibration controls not functioning
  Vibration hydraulic circuit, description
  Vibration motor, description
  Vibration pump, description
  Water pump, description
  Water spray system, description

Repair

• Adjustable steering column, replacing
  Air cleaner, installing
  Air cleaner, primary filter replacing
  Air cleaner, removing
  Air cleaner, secondary filter replacing
  Alternator, installing
  Alternator, removing
  Amplitude sensor, adjusting
  Batteries, replacing
  Battery disconnect switch (main switch), check
  Battery maintenance
  Breather, replacing
  Carrier bearings, replacing
  Charge air cooler pipe, installing
  Charge air cooler pipe, removing
  Charge air cooler, installing
  Charge air cooler, removing
  Connectors, position 2
  Connectors, position
  Control unit, description
  Coolant level, check
  Coolant mixture
  Coolant, changing
  Cooling fan, replacing
  Drive motor, installing
  Drive motor, removing]
  Drum carrier, changing oil
  Drum drive motor speed sensor, replacing
  Drum eccentric, changing oil
  Drum eccentric, checking oil level
  Drum shock mount, replacing 2
  Drum shock mount, replacing
  Drum shock mounts, checking
  Drum, checking
  Drum, installing
  Drum, removing
  Eccentric shaft coupling, replacing
  Eccentric weight bearings, replacing
  Eccentric weight, installing
  Eccentric weight, overhauling
  Eccentric weight, removing
  Electric and hydraulic control unit, replacing
  Engine hood, changing gas spring
  Engine hood, installing
  Engine hood, removing
  Engine mounts, replacing
  Engine oil and filter, changing
  Engine oil level, check
  Engine, air cleaner maintenance
  Engine, installing
  Engine, removing
  Fan belt and or alternator belt, replacing
  Fan belt, check
  Fan shroud, replacing
  Fuel filters, replacing
  Fuel level sender, replacing
  Fuel line, water separator, check and drain
  Fuel system, bleeding
  Fuel, coolant and oil leaks, checking
  Hand rail, installing
  Hand rail, removing
  Hydraulic oil cooler, installing
  Hydraulic oil cooler, removing
  Hydraulic oil filter, replacing
  Hydraulic oil suction strainer, cleaning
  Hydraulic oil tank, vacuum-pumping, connecting and disconnecting pump
  Hydraulic oil, changing
  Hydraulic pump, replacing
  Hydraulic system, checking oil level
  Hydrostatic controller, installing
  Hydrostatic controller, removing
  Hydrostatic pump, installing
  Hydrostatic pump, removing
  Loop flushing valve, replacing
  Maintenance service, every 10 hours
  Maintenance service, every 50 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 2000 hours
  Maintenance service, every 3000 hours
  Maintenance service, every 6000 hours
  Maintenance service, first 50 hours
  Multi function brake valve solenoid and cartridge, replacing 2
  Multi function brake valve solenoid and cartridge, replacing
  Multi-pin breakout box, connecting
  Oil and filtration
  Operation numbers for additional work
  Operator’s platform mounts, replacing
  Operator’s protective structure, component locations
  Operator’s seat, installing
  Operator’s seat, removing
  Parking brake performance
  Parking brake pressure switch, replacing 2
  Parking brake pressure switch, replacing
  Pump coupling, installing
  Pump coupling, removing
  Radiator and coolers, cleaning
  Radiator, replacing
  Reverse alarm, replacing
  ROPS (Roll Over Protection), installing
  ROPS (Roll Over Protection), removing
  Seat safety belt, replacing
  Silencer, replacing
  Smooth drum scrapers, replacing
  Starter motor, replacing
  Starter switch (engine start switch), replacing
  Steering control unit, installing
  Steering control unit, removing
  Steering cylinder, replacing
  Steering pressure, checking and adjusting
  Swivel joint (horizontal and vertical) pins, torque
  Torque hub, installing
  Torque hub, removing
  Two speed valve solenoid and cartridge, replacing
  Vibration motor, installing
  Vibration motor, removing
  Vibration pump, installing
  Vibration pump, removing
  Water filter, changing 2
  Water filter, changing
  Water pump strainer, checking
  Water pump, installing
  Water pump, removing
  Water tank and spray bars, drain and flush
  Water tank level, checking
  Water tank, installing
  Water tank, removing

Diagrams

• Component list, relays
  Electrical components, engine side
  Hydraulic diagram, schematic fig 1
  Hydraulic diagram, schematic no fig
  Hydraulic diagram
  Hydraulic diagram
  Wiring diagram 1
  Wiring diagram 1-2
  Wiring diagram 1-3
  Wiring diagram 1-4.jpg
  Wiring diagram 2
  Wiring diagram 2-1
  Wiring diagram 2-2
  Wiring diagram 2-4.jpg
  Wiring diagram 3
  Wiring diagram 3-1
  Wiring diagram 3-2
  Wiring diagram 3-3
  Wiring diagram 4
  Wiring diagram 4-1
  Wiring diagram 4-3
  Wiring diagram 5
  Wiring diagram 6
  Wiring diagram 7
  Wiring diagram 8
  Wiring diagram 9
  Wiring diagram 10
  Wiring diagram 11
  Wiring diagram 12
  Wiring diagram 13
  Wiring diagram 14

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