Volvo A25C 4×4 Articulated Dump Truck Repair Service Manual Workshop Guide

Manual Included: Repair Service Manual: 301 Pages Specifications: Brand: Volvo Model: A20 6×4 BM Type: Articulated Dump Truck Manuals: Repair Service Manual Publication Numbers: Ref. No 252954 3588 Language: English Format: PDF Description Table of Content A25C 4×4 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. ހ"11100, BR ހ"70300, US 66 ހ"61400, 44 ހ"68200) Instrument panel, (serial no. 11101Ţ€", BRł 70301Ţ€", US 66 61401Ţ€", 44 68201Ţ€") Wiring diagrams (serial no. ހ"11100, BR ހ"70300, US 66 ހ"61400, 44 ހ"68200) Circuit 0ހ"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. ހ"11100, BR ހ"70300, US 66 ހ"61400, 44 ހ"68200) (serial no. 11101ހ", BR 70301ހ", US 66 61401 ހ", 44 68201ހ") Fuses, left electrical distribution box Fuses, right electrical distribution box Other fuses(serial no. ހ"11100, BR ހ"70300, US 66 ހ"61400, (serial no. 11101ހ", BR 70301ހ", US 66 61401 ހ", 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 ހ"93283 Transmission functions, checking instructions for connector X1/A1 Transmission PT1051 ހ" 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 ހ" 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. ހ"11100, BR ހ"70300, US 66 ހ"61400, US 44 ހ"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