Volvo A25E and A25E 4x4 Articulated Hauler Workshop Repair Service Manual PDF - MVOLCOA25E.zip
A full-service repair guide, complete with electrical wiring schematics, for the Articulated Haulers A25E Volvo / A25E Volvo 4x4, offering the technical detail needed to service, troubleshoot, and maintain these machines just as trained technicians do.
Contained within this Articulated Haulers A25E Volvo / A25E Volvo 4x4 workshop service and repair manual:
* 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.
Articulated Haulers A25E Volvo, A25E Volvo 4x4 Service Repair Manual.pdf
PRODUCT DETAILS:
Pages: 2,378
File Format: PDF (Windows & Mac & Linux)
Language: English
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
...
TABLE OF CONTENTS
0 - Foreword...2
0 - GENERAL...3
00 - DESCRIPTION; COMPLETE MACHINE...4
Axles, A25E 4×4...4
Body lock, A25E 4×4...5
Brakes, A25E 4x4...6
Description, A25E 4×4...7
Ground pressure...8
Information and warning decals...9
Load capacity...12
Steering cylinder, description...13
Turn-around wheel equipment, A25ETR 4×4...15
Turn-around wheels, specifications...16
03 - SPECIFICATIONS...17
Capacities...17
Coolant with anti-freeze and corrosion protection, recommendation...18
Machine dimensions...20
Power take-off, tightening torque...24
Rocker arm shaft, tightening torques ...26
Tightening torques...28
Tyre equipment and recommended tyre pressures...37
Weights...38
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...39
Lifting machine...39
Recovering and towing ...42
07 - STANDARD TIME...44
Operation numbers for additional work...44
08 - TOOL...46
88830051 User Instruction...46
E-1750...56
E-1763...57
E-2502...59
E-2503...61
E-2519...62
E-2520...64
E-2526...66
E-2548...68
Infrared Thermometer...70
09 - MISCELLANEOUS...74
Appointment and distribution of responsibility...74
Basic check, transmission...75
Basic checks...76
Brake system, basic check...78
Collection of basic data...80
Dealers_retrofitter´s responsibility...83
Electrical system, basic check ...84
Engine, basic check...88
Parking brake, basic check...92
Power transmission, basic check...94
Steering and hydraulics, basic check...96
Troubleshooting strategy ...98
Troubleshooting, General...101
Troubleshooting, assistant devices...102
VCADS Pro service tool, general...103
VCADS Pro tests...105
VCADS Pro, Calibrating...109
VCADS Pro, Error codes...111
VCADS Pro, Programming...113
VCADS Pro, Test...116
1 - STANDARD PARTS, SERVICE...118
16 - LUBRICANT; FUEL; OTHER FLUID...119
Alternative fuels...119
Recommended lubricants...122
17 - SERVICE...124
Air drier, drier cartridge, replace...124
Arrival Inspection, according to Inspection Programme...125
Axle mounts, bolted joints, tourque, check...126
Battery, charging state, electrolyte level, cables and connections, especially connections at starter motor, check...127
Brake fluid level, check...129
Brake fluid, change...131
Brake pipes and hoses, check...133
Cab main filter, replacing...134
Cab, asbestos filter, replacing...135
Cab, prefilter, replace...136
Compressed air system, drain...137
Condenser, clean (with compressed air) (optional equipment)...139
Condition test and maintenance program...140
Coolant's freezing point, check...142
Coolant, changing ...143
Cooling fan, return oil filter, replacing...147
Delivery Inspection, according to Inspection Programme...149
Drive axles and hubs, oil, replace...150
Drive axles, transmission and dropbox, breather filter, replace...153
Dropbox, oil, replace...155
Dump body alternative, lowering...157
Engine mounts_dropbox mounts_propeller shafts, bolted joints and flange mounts, check torques...159
Engine, air cleaner, cover, clean...163
Engine, air cleaner, secondary filter, replace. EON (option) only when indicated...164
Frame joint bearings, clearance, check...166
Fuel filters, primary and secondary filter, replace...168
Fuel tank, hydraulic oil tank, breather filter replace...170
Fuel, coolant and oil leakage, check...172
Hydraulic oil tank, return oil filter, replace, and magnetic rods, clean...173
Load body, exhaust heated, check_clean_grease...175
Load body, rubber cushions, clearance, check...178
Lubrication, see lubrication chart...180
MATRIS, reading, export reading...181
Maintenance of Stored Machines, according to Inspection Programme...182
Maintenance service, daily...183
Maintenance service, every 1000 hours...184
Maintenance service, every 2000 hours...186
Maintenance service, every 250 hours...189
Maintenance service, every 4000 hours...190
Maintenance service, every 50 hours...193
Maintenance service, every 500 hours...194
Maintenance service, every 6000 hours...196
Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change...199
Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean...200
Oil-bath air cleaner's reservoir (optional equipment), oil, check...201
Parking brake pads, check...203
Parking brake, manually releasing...204
Power take-off suction strainer, cleaning...206
Radiator, clean (from fan side with compressed air)...208
Recovering and towing...209
Safety when servicing...211
Service brake, brake pads, check...213
Service journal (included in Operator's manual), fill in...215
Steering cylinder bearings, clearance, check...216
Test-run and check...218
Transporting the machine...219
Tyres, wear and air pressure, checking...221
VCADS Pro, logged errors, read off...222
Valve clearance, check_adjust...223
Warranty inspection 100 hours...224
Warranty inspection 1000 hours...226
Warranty inspection...228
19 - GENERAL...229
CE-marking, EMC-directive...229
Checking function...233
Checklist after a fire or heat exposure...235
Cleanliness, brake and hydraulic systems...238
Decontamination...239
Environment...243
Environmental handling for the future...245
Environmentally hazardous fluids...247
Environmentally safe handling...250
Fire prevention measures...252
Health hazards with paint, plastics and rubber...255
Refrigerant for air conditioning...258
Rules when handling tyres...259
Safety concerns everybody!...262
Safety during electric welding...266
Safety when handling accumulators_{12-29-17}...267
Safety when handling accumulators_{12-30-13}...268
Safety when handling oils and fuel...269
Safety when handling the machine...270
Safety when lifting and supporting the machine...274
Safety when using lifting equipment...276
Safety when working on hydraulic systems...278
Safety when working on pressurized systems...280
Safety when working on the machine's electrical system...282
Safety when working with batteries...283
Service position 1...285
Starting with booster batteries...288
Waste handling...289
Working in environmentally contaminated areas...293
2 - ENGINE WITH MOUNTING AND EQUIPMENT...296
20 - GENERAL...297
E-ECU MID 128 non-programmed, replacing...297
E-ECU MID 128 pre-programmed, replacing...300
Engine, capacities...302
Engine, description...303
Engine, identification...305
Engine, sensor locations...307
Engine, weights...309
Tightening torques, engine mounts...310
21 - ENGINE...312
Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope...312
Camshaft setting, checking...318
Camshaft, description...327
Camshaft, replacing...328
Crankshaft and vibration damper, description...341
Crankshaft front oil seal, replacing...344
Crankshaft rear oil seal, replacing...350
Cylinder block, description...357
Cylinder compression, PC test...359
Cylinder compression, testing...360
Cylinder head gasket, description...369
Cylinder head guides...370
Cylinder head, description...372
Cylinder liners and pistons, description...373
Double rocker arm, description...378
Engine and transmission, installing...383
Engine and transmission, removing...405
Engine mount rubber cushion, replacing...428
Engine mounting rear, changing...432
Engine rotation speed sensor (camshaft), replacing...436
Engine rotation speed sensor, replacing...440
Engine timing gear, description...444
Engine transmission, specification...447
Engine, general specifications...450
Flywheel, tightening torques...452
Oil level sensor, replacing...454
Oil sump gasket, replacing...460
Oil sump, description...466
Oil sump, tightening torque...468
Oil trap, description...470
Rocker arm shaft, tightening torques...471
Tightening torque, cylinder head...473
Tightening torques, valve cover...474
Valve mechanism, description...475
Valve mechanism, specifications...477
Valves, adjusting...479
22 - LUBRICATING SYSTEM...486
Lubrication oil pressure, checking with pressure gauge...486
Lubrication system, specifications...488
Oil cooler, replacing...489
Oil cooler, tightening torques...494
Piston cooling system, description...495
23 - FUEL SYSTEM...497
Air in fuel system, checking...497
Carbon dioxide in fuel system, checking...501
Cylinder balancing, PC test...507
Feed pump pressure, checking...508
Fuel feed pump, description...510
Fuel feed pump, specifications...511
Fuel filter housing, description...512
Fuel flow, description...515
Fuel pump, inspecting...518
Fuel system, bleeding...523
Fuel system, tightening torques...525
Injector sleeves, replacing...531
Overflow valve, checking...541
Stall speed, checking...544
Unit injector pretension, adjusting...547
Unit injector, replacing...549
Unit injectors, description...557
Unit injectors, specifications...560
Water separator...561
25 - INLET & EXHAUST SYSTEM...562
Air cleaner, preheating coil, specifications...562
Air intake and filter...563
By-pass valve (wastegate)...564
Charge air cooler, replacing...566
Cooling fan motor, charge air cooler, checking_adjusting high rpm...573
Cooling fan motor, charge air cooler, checking_adjusting low rpm...577
Exhaust brake, description...581
Exhaust pressure governor (EPG), description...583
Fan pump, installing-[2146]...586
Fan pump, removing-[2214]...587
Hydraulic cooling fan control, PC test ...588
Intercooler, specifications...589
Preheating coil, replacing...590
Turbocharger, inspecting...593
Turbocharger, replacing...596
26 - COOLING SYSTEM...603
Coolant pump, reconditioning...603
Coolant pump, replacing...610
Coolant, changing...622
Cooling fan motor, radiator, checking_adjusting high rpm...626
Cooling fan motor, radiator, checking_adjusting low rpm...630
Cooling fan motor, specifications...634
Cooling system specifications...635
Cooling system, description...637
Cooling system, flushing...638
Cooling system, tightening torques...643
Fan pump, installing...645
Fan pump, removing...646
Fan system, description...647
Hydraulic cooling fan control, PC test...648
Radiator, adjusting...649
Radiator, installing...651
Radiator, removing...658
Thermostat, replacing...664
Thermostat, specifications...670
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...671
30 - GENERAL...672
10F9101, engine-dependent steering pressure, hydraulics...672
10F9102, ground-dependent steering pressure, hydraulics...674
10F9103 hydraulic oil, level in tank...677
10F9105, hydraulic oil, temperature...679
10F9108, hydraulic pump, shut-off...681