Volvo DD138HF Drum Compactor Service and Repair Manual PDF

Volvo DD138HF Drum Compactor Service and Repair Manual PDF

Size: 73.89 MB
Language: English
Make: Volvo
Machine: Drum Compactor
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo DD138HF
Page: 4058 Pages

Detail Contents:
1 Volvo DD138HF
Description

• Air cleaner, description
  Alternator, description
  Cable; Battery isolation switch
  Charge air cooler, description
  Component list, Fuses
  Conversion tables
  Cooling system, description
  Description, complete machine
  Drum drive motor, description Figure 1
  Drum drive motor, description
  Drum eccentric, description
  Drum, description
  Electric welding
  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
  Hydraulic oil, specifications1
  Hydraulic system, startup procedure
  Hydrostatic pump, description
  Instruments and controls, overview
  Loop flushing valve, description
  Low engine oil pressure
  Low voltage
  Lubricant recommendation
  Machine identification
  Multi-function brake valve, description Figure 1
  Multi-function brake valve, description
  Operator’s protective structure, description
  Paint and Finish
  Power train, troubleshooting
  Power Transmission, Propulsion
  Precaution when working on the electrical system
  Pump de-stroke valve and solenoid, description
  Safety when working on hydraulic system
  Safety when working on the electrical system
  Service position
  Service position1
  Smart functions, description
  Starter motor, description
  Starting with booster batteries
  Steering system, description
  Steering system, troubleshooting
  Thread locking compound, application specifications
  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 Figure 1
  Water spray system, description

Diagrams

• Component list, Relays
  Electrical components, engine side
  Hydraulic diagram Figure 1
  Hydraulic diagram, schematic Figure 1
  Hydraulic diagram, schematic
  Hydraulic diagram
  Wiring diagram 1 Figure 1
  Wiring diagram 1
  Wiring diagram 1-1 Figure 1
  Wiring diagram 1-1
  Wiring diagram 1-2 Figure 1
  Wiring diagram 1-2
  Wiring diagram 1-3 Figure 1
  Wiring diagram 1-3
  Wiring diagram 2 Figure 1
  Wiring diagram 2
  Wiring diagram 2-1 Figure 1
  Wiring diagram 2-1
  Wiring diagram 2-2 Figure 1
  Wiring diagram 2-2
  Wiring diagram 2-3 Figure 1
  Wiring diagram 2-3
  Wiring diagram 3 Figure 1
  Wiring diagram 3
  Wiring diagram 3-1 Figure 1
  Wiring diagram 3-1
  Wiring diagram 3-2 Figure 1
  Wiring diagram 3-2
  Wiring diagram 3-3 Figure 1
  Wiring diagram 3-3
  Wiring diagram 4 Figure 1
  Wiring diagram 4
  Wiring diagram 4-1 Figure 1
  Wiring diagram 4-1
  Wiring diagram 4-2 Figure 1
  Wiring diagram 4-2
  Wiring diagram 5 Figure 1
  Wiring diagram 5
  Wiring diagram 6 Figure 1
  Wiring diagram 6
  Wiring diagram 7 Figure 1
  Wiring diagram 7
  Wiring diagram 8 Figure 1
  Wiring diagram 8
  Wiring diagram 9 Figure 1
  Wiring diagram 9
  Wiring diagram 10 Figure 1
  Wiring diagram 10
  Wiring diagram 11 Figure 1
  Wiring diagram 11
  Wiring diagram 12 Figure 1
  Wiring diagram 12
  Wiring diagram 13 Figure 1
  Wiring diagram 13
  Wiring diagram 14 Figure 1
  Wiring diagram 14

Installation Instruction

• Back-up alarm, installing new
  Infrared temperature installation

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
  Cleaning engine compartment1
  Cleaning engine compartment2
  Cleaning of the machine1
  Cleaning of the machine2
  Connectors, position1
  Connectors, position2
  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
  Drum shock mount, replacing1
  Drum shock mounts, checking
  Drum, checking
  Drum, installing
  Drum, removing
  Eccentric shaft coupling, replacing
  Eccentric weight bearings, replacing
  Eccentric weight, installing
  Eccentric weight, overhaul
  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 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
  Lubrication and service chart
  Lubrication and service schedules
  Maintenance service, daily1
  Maintenance service, daily2
  Maintenance service, every 50 hours1
  Maintenance service, every 50 hours2
  Maintenance service, every 50 hours3
  Maintenance service, every 50 hours4
  Maintenance service, every 500 hours1
  Maintenance service, every 500 hours2
  Maintenance service, every 1000 hours1
  Maintenance service, every 1000 hours2
  Maintenance service, general
  Multi function brake valve solenoid and cartridge, replacing
  Multi function brake valve solenoid and cartridge, replacing1
  Multi-pin breakout box, connecting
  Oil and filtration
  Oil and filtration1
  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
  Parking brake pressure switch, replacing1
  Periodic maintenance
  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
  Vibration speed sensor, replacing
  Water filter, changing
  Water filter, changing1
  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

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
    Health hazards with paint, plastics and rubber1
    Safe operation of the machine
    Safety concerns everybody!
    Safety concerns everybody!1
    Safety when handling oil and fuel
    Safety when handling the machine
    Safety when handling the machine1
    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
  • Drum drive motor hollow center shaft repair procedure
    Drum Rubber Damper drum shocks
    Drum spray bar mounting bracket
    Fuel sampling, method
    Hydraulic oil dye
    Initial eccentric oil change interval
    Large DD and SD Carrier, new design on carrier assembly
    Lubricant specifications and service interval changes
    New TechTool VCADS Pro interface
    Portable refillable O-ring kits
    Preservation
    Reports
    Software Distribution Procedure
    Speed Sensor Adjustment Procedure
    Vibration speed sensor wiring support bracket
    Volvo Product incident accident report & Interview Form
  • Special Tools, Misc
  • 01 Time Guide Current generation
    11 Time Guide Previous generation
    21 Time Guide Old generation
    35 GRD G700B LabourTimeGuide
    40 RM Compaction Time guide
    41 RM Compaction ABG Time Guide
    42 RM Paving Systems ABG Time Guide
    Special tool catalog
    Special Tools Recommendations
  • Specifications
  • Battery, specifications
    Brake system, specifications
    Critical mounting torques
    Critical mounting torques1
    Drum, specifications
    Electrical system, specifications
    Engine, specifications
    Environmental requirements
    Fuel, lubricant and filling capacities
    Fuels, lubricants and filling capacities (litres)
    Fuels, lubricants and filling capacities (litres)1
    Hydraulic connections, tightening torques
    Hydraulic connections, tightening torques1
    Hydraulic motor, specifications
    Hydraulic motor, specifications1
    Hydraulic motor, specifications2
    Hydraulic pump, specifications
    Location of components
    Lubrication and oil system, general specifications
    Lubrication and oil system, general specifications1
    Machine dimensions
    Machine weight, specifications
    Power transmission, specifications
    Specifications, general
    Steering system, specifications
    Steering system, specifications1
    Tightening torque, specifications1
    Tightening torque, specifications2
    Tightening torque, specifications3
    Tightening torque, specifications4

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