Volvo A45G and A45G FS Articulated Haulers Workshop Repair Service Manual PDF - MVLVCONA45G.zip
Full workshop and repair guide, complete with electrical wiring schematics, for the Volvo Construction A45G and A45G FS Articulated Haulers — everything a professional technician needs to service, troubleshoot, fix and rebuild these machines.
The Volvo A45G and A45G FS Articulated Hauler workshop service and repair manual contains:
* 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 A45G Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,102 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Complete machine; descriptions....5
Product plates....8
Information and warning decals....11
03 - SPECIFICATIONS....23
Tyre equipment and recommended tyre pressures....24
Tightening torques....26
Weights....28
07 - STANDARD TIME....29
Operation numbers for additional work....30
08 - TOOL....32
E-1763....33
E-2005....34
E-2014....35
E-2016....36
E-2501....37
E-2502....38
E-2517....39
E-2518....41
E-2519....42
E-2520....43
E-2525....45
E-2526....46
E-2529....48
E-2534....49
E-2539....50
E-2546....51
E-2548....53
E-7029....55
E-7030....56
Infrared Thermometer....57
Leak detector 951 1207; description....58
88830227_88830228 User instruction....61
88830268 User Instruction....69
88830384 User instruction....74
88830386 User instruction....80
88830507 User instruction....84
88830508 User instruction....90
88830557 User Instruction....100
09 - MISCELLANEOUS....108
Troubleshooting strategy....109
Troubleshooting; assistant devices....110
Collection of basic data....111
Tech Tool; operations ....113
Basic checks....114
Engine; basic check....115
Electrical system; basic check....118
Power transmission; basic check....124
Basic check; transmission....127
Brake system; basic check....128
Parking brake; basic check....132
Steering and hydraulics; basic check....135
1 - STANDARD PARTS; SERVICE....137
16 - LUBRICANT; FUEL; OTHER FLUID....138
AdBlue_DEF....139
Automatic lubrication system....141
Coolant....142
Grease....143
Recommended lubricants....144
Alternative fuels....149
Exhaust heated dump body....152
17 - SERVICE....153
Service....156
Safety when servicing....158
Service points....159
Tech Tool; operations....161
Arrival Inspection; according to Inspection Programme....162
Delivery Inspection; according to Inspection Programme....163
Maintenance of Stored Machines; according to Inspection Programme....164
Condition test and maintenance program....165
Maintenance service; first 100 hours....166
Maintenance service; first 1000 hours....167
Maintenance service; every 50 hours....168
Maintenance service; every 4500 hours....169
Restoring from service position....170
Restoring of the machine....171
Lubrication; every 250 hours....173
Lubrication; every 500 hours....176
Lubrication; every 1000 hours....178
Lubrication; every 2000 hours....180
Basic service....181
Drive belts; checking....183
Engine and dropbox mounts; checking....185
Fuel filters; replacing....188
Extra fuel prefilter; replacing....193
Fuel system extra fuel pre- filter; draining....195
Fuel tank breather filter; replacing....196
Fuel tank sediment; draining....197
Air drier filter; replacing....198
EATS Heat protection; checking....201
Diesel particulate filter; checking and cleaning....203
EATS cooling fan; replacing....211
AdBlue_DEF tank breather filter; replacing....215
Engine air cleaner primary filter; replacing....216
Engine air cleaner secondary filter; replacing....218
Engine pre cleaner cyclone type; cleaning....220
Oil-bath air cleaner reservoir oil; checking....222
Oil-bath air cleaner reservoir oil; changing....224
Oil-bath air cleaner reservoir filter insert; cleaning....227
Coolant; changing....230
Radiator; cleaning....239
Engine and cab heater extra fuel tank breather filter; replacing....240
EGR venturi tube; cleaning....241
MATRIS and Tech Tool; reading....243
Software update; checking....244
Transmission oil; changing....246
Transmission oil filter; replacing....248
Transmission breather filter; replacing....250
Dropbox leakage; checking....251
Dropbox oil; changing....252
Dropbox and front axle; breather filter; replacing....254
Dropbox quick drain valve; replacing....255
Propeller shaft movement; checking....258
Drive axles leakage; checking....260
Drive axle oil; changing....261
Axle breather filters; replacing....263
Power take-off suction strainer; cleaning....265
Service brake disc wear; checking....267
Brake system pressure oil filter; replacing....269
Brake cooling oil level; checking....271
Brake cooling oil; changing....272
Brake cooling oil tank breather filter; replacing....276
Brake cooling tank return oil filter and magnetic rods; cleaning and replacing....277
Parking brake function; checking....282
Parking brake; checking and adjusting....283
Steering cylinder bearings clearance; checking....288
Secondary steering; checking....290
Frame extension bolted joints torque; checking....291
Frame joint bearings clearance; checking....292
Steering joint bearing; checking....294
Tyre wear and air pressure; checking....297
Alternative exit; checking....298
Cab prefilter; replacing....299
Cab main filter; replacing....301
Cab asbestos filter; replacing....303
Hydraulic oil level; checking....304
Hydraulic oil tank breather filter; replacing....305
Hydraulic tank sediment; draining....308
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing....310
Load weighing cable to load cell; checking....315
Load body rubber cushions clearance; checking....316
Exhaust heated load body; checking; cleaning and greasing....318
Fire suppression system; checking....320
Automatic lubrication system filter; replacing....343
Recovering and towing....345
Dump body alternative; lowering....349
Parking brake; manually releasing....351
Propeller shaft between transmission and dropbox; removing....353
Transporting the machine....358
19 - GENERAL....364
CE-marking; EMC-directive....365
FOPS and ROPS....367
Safety concerns everybody!....368
Safety when handling the machine....369
Service position 1....373
Safety when lifting and supporting the machine....376
Safety when using lifting equipment....377
Rules when handling tyres....378
Safety when working with batteries....380
Starting with booster batteries....382
Safety when handling oils and fuel....384
Safety when handling AdBlue_DEF....385
Safety when working on pressurized systems....386
Safety when working on hydraulic systems....387
Safety when handling accumulators....388
Safety when working on the machine's electrical system....389
Safety during electric welding....392
Fire prevention measures....393
Checklist after a fire or heat exposure....395
Health hazards with paint; plastics and rubber....396
Environment....398
Environmental handling for the future....399
Waste handling....400
Environmentally safe handling....401
Environmentally hazardous fluids....403
Safety when working with air conditioning refrigerant....404
Working in environmentally contaminated areas....406
Decontamination....407
2 - ENGINE WITH MOUNTING AND EQUIPMENT....408
20 - GENERAL....409
Engine; description_{08-10-00}....410
Engine; description_{08-09-37}....417
Engine; description_{08-09-15}....423
Tech Tool; operations_{08-08-15}....427
Tech Tool; operations_{08-07-56}....430
Tech Tool; operations_{08-07-37}....432
Tightening torques; engine mounts....434
Engine; capacities....436
Engine; sensor locations....437
E-ECU MID 128 pre-programmed; replacing....440
E-ECU MID 128 non-programmed; replacing_{08-05-37}....441
E-ECU MID 128 non-programmed; replacing_{08-05-15}....444
Engine; reference values....447
21 - ENGINE....450
Engine; specifications....451
Engine and transmission; removing....456
Engine and transmission; installing....485
Engine rotation speed sensor; replacing....512
Engine rotation speed sensor (camshaft); replacing....515
Engine; tightening torques....520
Cylinder compression; testing_{08-00-07}....531
Cylinder compression; testing_{07-59-34}....545
Cylinder compression; testing_{07-59-04}....559
Cylinder head; description....573
Crankcase ventilation; description_{07-57-31}....576
Crankcase ventilation; description_{07-57-09}....582
Crankcase ventilation separator; replacing....585
Cylinder block; description....589
Valve mechanism; specifications....593
Internal Exhaust Gas Recirculation (IEGR); description....596
Valves; adjusting_{07-53-34}....603
Valves; adjusting_{07-53-11}....614
Valve cover; removing....625
Valve cover; installing....628
Engine timing gear; description....633
Camshaft setting; checking....636
Camshaft; replacing....641
Crankshaft front oil seal; replacing....658
Crankshaft rear oil seal; replacing....663
Crankshaft; axial clearance; checking....670
Engine mount rubber cushion; replacing....675
Engine mounting rear; changing....679
22 - LUBRICATING SYSTEM....683
Lubrication system; description....684
Lubrication system; specifications....690
Lubrication oil consumption; checking....692
Lubrication system; component locations....696
Lubrication system; tightening torques....699
Lubrication oil pressure; checking with pressure gauge....703
Lubrication pressure rocker arm shaft; checking....705
23 - FUEL SYSTEM....710
Fuel system; description_{04-35-58}....711
Fuel system; description_{04-34-52}....717
Fuel system; specifications....726
Fuel system; tightening torques....728
Air in fuel system; checking....734
Carbon dioxide in fuel system; checking....739
Fuel system; component location....745
Feed pump pressure; checking....747
Fuel pump; inspecting....749
Fuel system; bleeding....766
Fuel level; description....770
Stall speed; checking....772
Unit injector pretension; adjusting....776
Injectors; checking....778
Yoke; injector; checking....789
Unit injector; replacing_{03-50-15}....794
Unit injector; replacing_{01-50-45}....808
Overflow valve; replacing....814
Injector sleeves; replacing_{12-49-40}....818
Injector sleeves; replacing_{12-46-23}....828
25 - INLET & EXHAUST SYSTEM....837
Inlet and exhaust system; description_{12-38-28}....839
Inlet and exhaust system; description_{12-36-30}....849
Inlet and exhaust system; description_{12-35-06}....854
Inlet and exhaust system; specification_{12-33-22}....859
Inlet and exhaust system; specification_{12-33-04}....861
Inlet and exhaust system; component location....864
Inlet and exhaust system; tightening torques_{12-31-47}....866
Inlet and exhaust system; tightening torques_{12-29-52}....873
Exhaust pipe flexible tube; replacing_{12-28-04}....879
Exhaust pipe flexible tube; replacing_{12-25-37}....884
Exhaust pipe flexible tube; replacing_{12-23-57}....888
Exhaust pipe flexible tube; replacing_{11-51-51}....893
Silencer; replacing....897
Compression brake; description....908
Auxiliary brake (engine braking); description_{10-49-51}....915
Auxiliary brake (engine braking); description_{10-49-30}....917
Exhaust pressure governor....920
Exhaust Aftertreatment System; description....923
Exhaust Aftertreatment System; component location....939
Regeneration process; description....944
AdBlue®_DEF tank; replacing....950
AdBlue®_DEF; draining....959
AdBlue®_DEF quality; checking....963
SCR (Selective catalytic reduction) dosing system; checking....966
AdBlue®_DEF pump unit diagnostics; description....971
Exhaust aftertreatment fuel system diagnostics; description....977
DPF (Diesel particulate filter); checking and cleaning....980
ACM (Aftertreatment control module) non-programmed; replacing....988
ACM (Aftertreatment control module) pre-programmed; replacing....992
NOx sensor; replacing....993