Volvo A25C Articulated Dump Truck Repair Service Manual

Description

Table of Content A25C Service Information

• GENERAL
  • DESCRIPTION, COMPLETE MACHINE
    • General
  • SPECIFICATIONS
    • • Specifications, tightening torques
      • Specifications, dimensions
      • Volvo standard tightening torques
  • STANDARD TIME
  • TOOL
    • • Drawings of E-tools that can be made in your own workshop

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
    • • Brake system, changing brake fluid
  • SERVICE
    • Maintenance
      • Electric welding
    • Emergency measures

• ENGINE WITH MOUNTING AND EQUIPMENT
  • ENGINE
    • General, common info about 211 – 218
      • Compression check, engine at operating temperature
      • Specifications, general
    • Cylinder head
      • Specifications, tightening torques
    • Cylinder block with crankcase ventilation
    • Valve mechanism
      • Valves, adjusting
    • Engine transmission; camshaft
    • Crank shaft; connecting rod; vibration damper; fly wheel
    • Oil sump, dipstick incl.
    • Engine mounting
  • LUBRICATING SYSTEM
    • General, common info about 221 – 224
    • Oil pump; line
      • Lubrication oil pressure, checking
  • FUEL SYSTEM
    • General (common info about 233 – 238)
      • Low emission engines
    • Fuel pump; filter; strainer
      • Fuel feed pump, checking feed pressure
    • Fuel tank; fuel filling pump
      • Specifications, capacities
    • Injection pump; regulator; pump companion
      • Fuel injection pump, changing incl. setting injection timing
      • Idle speed, checking and adjusting
      • Injection timing TDC, checking and adjusting
      • Low and high idle speed, checking and adjusting with service display unit
      • Stall speed, checking with service display unit
    • Injector; delivery pipe
      • Injectors, changing all
    • Control system; control unit (for ex. injection timming adjuster)
      • Automatic timing adjuster, checking
      • Automatic timing adjuster (alpha adjuster)
  • INLET SYSTEM; EXHAUST SYSTEM
    • Inlet manifold; exhaust manifold
    • Turbo charger
    • Air cleaner with connections; air pre-heater
  • COOLING SYSTEM
    • General, common info about 261 – 269
    • Radiator, mounting and connections included
      • Coolant, changing
    • Fan; fan shroud; fan coupling
      • Hydraulic motor for fan, alternatively hydraulic pump, checking internal leakage
      • Radiator fan drive, checking function of motor
      • Radiator fan drive, general description
  • ENGINE CONTROL
    • Revs control, foot operated
      • Throttle pedal, anti-throttle cylinder, adjusting

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • • Comprehensive info, electrical system
      • Special instructions for servicing the electrical system
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • Battery
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • Alternator inclusive drive
      • Charging, checking in machine (multimeter)
    • Charging; converter
  • STARTING SYSTEM
    • Starter motor inclusive solenoid
  • LIGHTING
    • General, common info about 351 – 356
    • Lighting, front, including parking light and day running light
      • Headlight, complete, changing 1 headlight incl. adjusting alignment
      • Headlights, adjusting against wall or fender
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
      • A25C 4×4 turn-around wheels (serial no. Ţ€“12483)
      • Explanations of wiring diagrams
      • Instrument panel, (serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400, 44 Ţ€“68200)
      • Instrument panel, (serial no. 11101Ţ€“, BRł 70301Ţ€“, US 66 61401Ţ€“, 44 68201Ţ€“)
      • Wiring diagrams (serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400, 44 Ţ€“68200) Circuit 0Ţ€“6
      • Wiring diagrams(serial no. 11101Ţ€“, BR 70301Ţ€“, US 66 61401Ţ€“, 44 68201Ţ€“) Circuit 0Ţ€“6
    • Cable; battery disconnector
      • Code legend for connectors (serial no. 11101Ţ€“, BR 70301Ţ€“, US 6×6 61401Ţ€“, 4×4 68201Ţ€“)
      • Code legend for connectors (serial no. Ţ€“11100, BR Ţ€“70300, US 6×6 Ţ€“61400, 4×4 Ţ€“68200)
      • Template for pin numbers connector X1/A1
    • Electrical distribution box; fuse box; junction box
      • Circuit board, right electrical distribution box(serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400, 44 Ţ€“68200)
      • (serial no. 11101Ţ€“, BR 70301Ţ€“, US 66 61401 Ţ€“, 44 68201Ţ€“)
      • Fuses, left electrical distribution box
      • Fuses, right electrical distribution box
      • Other fuses(serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400,
      • (serial no. 11101Ţ€“, BR 70301Ţ€“, US 66 61401 Ţ€“,
      • Relays, left electrical distribution box
      • Relays, right electrical distribution box
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
    • Speedometer; trip meter; hour counter
      • Speedometer, changing (serial no. 10742Ţ€“11965, BR 70173Ţ€“70388, US 66 61103Ţ€“61623, 44 68157Ţ€“68218)
      • Speedometer, electric, calibrating
      • Speedometer, electronic programming instructions
      • Speedometer, electronic, description (serial no. 11966Ţ€“, BR 70389Ţ€“, US 6×6 61624 Ţ€“, 4×4 68211Ţ€“)
    • Sender, monitoring system
      • Load sensor, checking electric circuits
      • Load sensor, adjusting
    • Warning/information unit, display unit
      • Contronic Information Display Unit
      • Contronic service display unit
      • Information display unit, summary
      • Information on the service display unit
      • Measuring instrument, summary
      • Service display unit, summary
      • Using the service display unit

• POWER TRANSMISSION
  • • General, common info about 410 – 436
  • CLUTCH; TORQUE CONVERTER
    • Hydrodynamic coupling, torque converter
  • TRANSMISSION, HYDRAULIC CONTROL
    • • Hydraulic diagram, transmission with retarder from and incl. serial number 93284Ţ€“
      • up to and incl. serial number Ţ€“93283
      • Transmission functions, checking instructions for connector X1/A1
      • Transmission PT1051 Ţ€“ cut-away drawing
      • Transmission PT1051, general description
      • Transmission, general troubleshooting
      • Troubleshooting outside the control unit in connector X1/A1
      • Wiring diagram, transmission electronics, circuit 37a-I
    • Transmission, hydraulic control
      • Diagnosis using error codes on service display unit
      • Gearshift selector, checking
      • Hydraulic transmission, checking oil pressure
      • Inductive sensor for output shaft, changing
      • Inductive sensor for turbine speed, changing
      • Oil cooler, changing
      • Seal for rear output shaft, changing
      • Solenoids, checking resistance
      • Transmission, removing and mounting (engine removed from machine)
      • Transmission, removing and mounting (together with engine)
  • GEARBOX,
    • Distributing gearbox
      • Dropbox FL 652 C, general description
      • Dropbox, adjusting high and low range
      • Dropbox, changing compressed air cylinder for high and low range
      • Dropbox, changing seal for rear output shaft
      • Dropbox, changing seal for front output shaft
      • Longitudinal differential lock, adjusting engagement
  • PROPELLER SHAFT
    • General, common info about 451 – 453
    • Propeller shaft, complete
      • Intermediate propeller shaft and/or bearing, changing (in frame joint)
      • Propeller shaft between transmission and dropbox, changing
      • Propeller shaft for rear bogie axle, changing
      • Propeller shaft, front output shaft on dropbox, changing
      • Propeller shaft for front bogie axle, changing
  • FRONT AXLE; REAR AXLE
    • General, common info about 461 – 468
      • Dog clutch 66, checking and adjusting
      • Final drive 66 output shaft, changing seals and bearings
    • Front axle
      • Front axle complete, removing
    • Differential lock, with control
      • Transverse differential lock, adjusting engagement (per axle)
  • POWER TAKE OFF
    • Power take off
    • Power take off, between engine and gearbox (ART)
      • Flywheel housing (rear engine transmission) and power take-off
      • Power take-off in flywheel housing, reconditioning
      • Power take-off in flywheel housing, changing

• BRAKE
  • • Comprehensive info about brakes
  • WHEEL BRAKE
    • General, common info about 511 – 519
      • Brake pads for service brake, checking
      • Specifications, weights
    • Front wheel brake, dry brake
      • Brake caliper, changing (per caliper)
      • Brake disc, changing
  • HYDRAULIC BRAKE SYSTEM
    • General, common info about 520 – 522
      • Brake system, bleeding
    • Brake valve
  • PARKING BRAKE
    • General, common info about 551 – 554
      • Parking brake caliper removed, reconditioning
      • Parking brake valve Ţ€“ hand-operated lever
      • Parking brake valve, reconditioning
      • Parking brake, changing brake caliper
      • Parking brake, changing brake disc
      • Parking brake, changing brake pads
      • Spring brake cylinder removed, reconditioning
    • Propeller shaft brake
  • COMPRESSED-AIR BRAKE
    • General, common info about 561 – 565
      • Blocking valve, reconditioning (removed)
      • Four-way pressure retaining valve, reconditioning (removed)
    • Compressor; regulator; anti-freez unit
      • Cut-out and cut-in pressures, checking and adjusting
      • Cut-out and cut-in pressures, checking and adjusting
    • Compressed-air tank, with mounting
    • Valves, compressed-air
  • MISCELLANEOUS
    • General, common info about 591 – 594
      • Compressed air diagram A25C, 4×4 turn-around wheels (serial no. 11101Ţ€“, BR 70301Ţ€“, US 66 61401 Ţ€“, 44 68201Ţ€“)
      • Compressed air diagram A25CTS 6×6 (serial no. Ţ€“12191)
      • (serial no. 12192Ţ€“)
      • Compressed air diagram A25C, 4×4 turn-around wheels (serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400, US 44 Ţ€“68200)
      • Compressed air diagram A25C US 44 68201Ţ€“)
      • Compressed air diagram A25C(serial no. Ţ€“11100, BR Ţ€“70300, US 66 Ţ€“61400, US 44 Ţ€“68200)
    • Retarder
      • Functional description, hydraulic retarder

• STEERING
  • • Comprehensive info, steering
  • • General, common info about 641 – 647
      • Pressure accumulation, engine dependent pumps 1 and 2
    • Steering gear
      • Steering gear, checking and adjusting
      • Steering gear, changing
    • Steering arm; steering linkage; track rod
      • Steering linkage, changing roller bearings in rear lever
      • Steering linkage, changing roller bearing in front lever
      • Steering linkage, checking and adjusting
    • Hydraulic equipment
      • Damping cylinder, removing and mounting
      • Damping cylinder, changing seals
      • Damping cylinder, checking pre-load
      • Steering cylinder bearing, checking
      • Steering cylinder, changing spherical bearing
      • Steering cylinder, reconditioning in machine (left steering cylinder)
      • Steering valve removed, reconditioning
      • Steering valve, changing
      • Steering cylinder, changing
      • Steering system, checking and adjusting operating pressure
      • Steering valve neutral position and valve slide axial clearance, checking
    • Steering damper

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • FRAME
    • Frame, complete
      • Load unit frame, checking dimensions
  • SUSPENSION
    • General, common info about 725 – 727
    • Hollow rubber spring, bump stop
      • Front rubber springs, changing all
  • FRAME LINK
    • Bearings
      • Frame joint, checking and adjusting clearance
      • Frame joint, changing metallic bearing
      • Steering joint and frame joint
    • Frame link grader
      • Frame joint, changing hitch
      • Steering joint, changing spherical bearings
  • AXLE SUSPENSION
    • Movable member system, front/rear
      • A-frame rubber bushing brackets, adjusting front bracket
      • Front or rear bogie axle torsion bar, adjusting
      • Front axle, changing rubber spring (bushing)
      • Load unit A-frame, changing rubber spring (bushing)
    • Bogie suspension
      • Bogie beam, changing rubber springs
      • Torsion bar and/or rubber bushing, changing on load unit
      • Torsion bar, checking and adjusting
  • WHEELS; TRACKS; TYRE; HUB; DRUM
    • Wheel

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • CAB, NAKED; CANOPY
  • TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
    • Glass; sealing moulding
      • Window pane, changing
  • CAB INTERIOR/UPHOLSTERY
    • Driver’s seat, complete; instructor’s seat
      • Air spring for operatorŢ€™s seat, changing
      • OperatorŢ€™s seat, adjusting height of attachment
      • OperatorŢ€™s seat, mechanical suspension
  • AIR CONDITIONING UNIT
    • Air distribution incl. air intake with filter
    • Heating unit
      • Heater, changing
    • Cooling unit
      • Filling refrigerant R134a

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • Hydraulic system and component positions
      • Hydraulic system, bleeding air
    • Tank; line; oil cooling; filter; breather; filling pump
    • Working hydraulics
    • Pump, working hydraulics
      • Oil pump, changing ground dependent pump
      • Oil pump, checking and adjusting hold (standby) pressure
  • LOAD CARRIER
    • Hauler/platform body, incl. tipping cylinder; heating; tail gate
      • Adjusting shims, checking and adjusting lateral position
      • Dump lever, adjusting
      • Dumping valve, changing
      • Dumping valve, changing cable
      • Hoist cylinder removed, reconditioning
      • Hoist cylinder, changing
      • Installing piston rod seals
      • Load body position indicator, adjusting
      • Load body, adjusting against frame
  • • General, common info about 992 – 996
      • Hydraulic diagram A25C 6×6