Volvo A25D & A25D 4x4 Articulated Hauler Workshop Repair Service Manual PDF - MVOLCOA25D.zip
A full-service repair manual featuring electrical wiring schematics for the Volvo A25D Articulated Hauler / Volvo A25D 4x4, packed with the technical details needed to service, troubleshoot, and maintain the machine the way expert technicians do.
The Volvo Construction Equipment A25D 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.
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
Volvo Articulated Haulers A025D & 4x4 Service Repair Manual.pdf
PRODUCT DETAILS:
Pages: 3,961
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Axles, A25D 4×4....4
Body lock, A25D 4×4....5
Brakes, A25D 4×4....6
Ground pressure....7
Hydraulics....8
Information and warning decals....10
Load capacity....13
Product identification plates....14
Steering cylinder, description....16
Turn-around wheel equipment, A25DTR 4×4....21
Turn-around wheels, specifications....22
03 - SPECIFICATIONS....23
Coolant with freezing and corrosion protection....23
Dumping angle, A25D 4×4, specifications....24
Lubrication system, specifications-[2637]....25
Machine dimensions....26
Rear frame A25D 4×4, overview illustration....29
Rear frame A25D 4×4, tightening torques....30
Rocker arm shaft, tightening torques-[2931]....32
Tightening torques....34
Tire equipment and recommended air pressure, A25D 4×4....43
Weights....44
07 - STANDARD TIME....45
Operation numbers for additional work....45
08 - TOOL....47
88830051 User Instruction....47
E-1763....57
E-2502....59
E-2516....61
E-2519....62
E-2526....64
09 - MISCELLANEOUS....66
Appointment and distribution of responsibility....66
Basic check, transmission....67
Basic checks....68
Brake system, basic check....70
Collection of basic data....72
Dealers_retrofitter´s responsibility....75
Electrical system, basic check....76
Engine, basic check....80
Parking brake, basic check_{03-08-51}....84
Parking brake, basic check_{03-09-19}....86
Power transmission, basic check_{03-11-16}....88
Power transmission, basic check_{03-11-45}....90
Steering and hydraulics, basic check....92
Troubleshooting strategy ....94
Troubleshooting, assistant devices....97
Troubleshooting, general....98
VCADS Pro service tool, general....99
VCADS Pro tests-[1444]....101
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
Lubrication and service schedules....122
Recommended lubricants....123
17 - SERVICE....125
Arrival Inspection, according to Inspection Programme....125
Brake pipes and hoses, check....126
Condition test and maintenance program....127
Coolant's freezing point, check....129
Coolant, changing_{02-48-06}....130
Coolant, changing_{02-48-43}....134
Delivery Inspection, according to Inspection Programme....138
Dump body alternative, lowering ....139
Fuel, coolant and oil leakage, check....142
Lubrication, see lubrication chart....143
MATRIS, reading, export reading....144
Maintenance of Stored Machines, according to Inspection Programme....145
Maintenance service, daily....146
Maintenance service, every 1000 hours....148
Maintenance service, every 2000 hours....171
Maintenance service, every 250 hours....208
Maintenance service, every 50 hours....214
Maintenance service, every 500 hours....219
Mechanical release of parking brake....234
Power take-off suction strainer, cleaning....236
Recovering and towing-[4552]....238
Recovering and towing....240
Service brake, brake pads, check....242
Service journal (included in Operator's manual), fill in....244
Service....245
Transporting the machine....246
VCADS Pro, logged errors, read off....248
Warranty inspection 100 hours....249
Warranty inspection 1000 hours_{03-02-09}....251
Warranty inspection 1000 hours_{03-02-33}....254
Warranty inspection....257
19 - GENERAL....258
CE-marking, EMC-directive....258
Checklist after a fire or heat exposure....262
Cleanliness, brake and hydraulic systems....265
Decontamination....266
Environment....270
Environmental handling for the future....272
Environmentally hazardous fluids....274
Environmentally safe handling....277
Fire prevention measures....279
Health hazards with paint, plastics and rubber....282
Refrigerant for air conditioning....285
Rules when handling tyres....286
Safety concerns everybody!....289
Safety during electric welding....293
Safety when handling accumulators_{02-33-47}....294
Safety when handling accumulators_{02-34-15}....295
Safety when handling oils and fuel....296
Safety when handling the machine....297
Safety when lifting and supporting the machine....301
Safety when using lifting equipment....303
Safety when working on hydraulic systems....305
Safety when working on pressurized systems....307
Safety when working on the machine's electrical system....309
Safety when working with batteries....310
Service position 1....312
Starting with booster batteries....314
Waste handling....315
Working in environmentally contaminated areas....319
2 - ENGINE WITH MOUNTING AND EQUIPMENT....322
20 - GENERAL....323
E-ECU MID 128 non-programmed, replacing_{02-22-17}....323
E-ECU MID 128 non-programmed, replacing_{02-23-09}....328
E-ECU MID 128 non-programmed, replacing_{02-23-38}....332
E-ECU MID 128 pre-programmed, replacing_{05-26-45}....335
E-ECU MID 128 pre-programmed, replacing_{05-27-03}....337
E-ECU MID 128 pre-programmed, replacing_{05-27-09}....338
Engine, description....340
Engine, identification....343
Engine, sensor locations....345
Engine, tightening torques....347
Engine, weights....352
Tightening torques, engine mounts....353
21 - ENGINE....355
Camshaft setting, checking....355
Camshaft, description....364
Camshaft, replacing....366
Crankshaft and vibration damper, description....379
Crankshaft front oil seal, replacing_{11-34-46}....383
Crankshaft front oil seal, replacing_{11-35-22}....391
Crankshaft rear oil seal, replacing....397
Cylinder block, description....404
Cylinder compression, PC test....407
Cylinder compression, testing-[5811]....408
Cylinder compression, testing....413
Cylinder head gasket, description....422
Cylinder head guides....424
Cylinder head, description....426
Cylinder liners and pistons, description....429
Double rocker arm, description....435
Engine and transmission, installing_{12-01-27}....440
Engine and transmission, mounting, version 1_{11-57-24}....462
Engine and transmission, mounting, version 2_{11-59-24}....479
Engine and transmission, removing, version 1_{12-04-12}....501
Engine and transmission, removing, version 2_{12-24-54}....520
Engine and transmission, removing_{12-50-42}....532
Engine mount rubber cushion, replacing....555
Engine mounting rear, changing....559
Engine rotation speed sensor (camshaft), replacing....563
Engine rotation speed sensor, replacing....567
Engine timing gear, description....571
Engine transmission, specification....575
Engine, general specifications....578
Engine, mounting....583
Engine, removing....600
Flywheel housing with power take-off (PTO), mounting on engine out of machine....622
Flywheel housing with power take-off (PTO), removing from engine out of machine....626
Flywheel, tightening torques....631
Oil level sensor, replacing....633
Oil sump gasket, replacing....639
Oil sump, description....645
Oil sump, tightening torque....647
Oil trap, description....649
Rocker arm shaft, tightening torques....650
Tightening torque, cylinder head....652
Tightening torques, valve cover....653
Valve mechanism, description....654
Valves and unit injectors, adjusting – D9A_{11-43-22}....658
Valves, adjusting_{11-42-50}....663
Valves, adjusting_{11-44-01}....667
22 - LUBRICATING SYSTEM....674
Lubrication oil pressure, checking with pressure gauge....674
Lubrication oil pump and oil cooler, description....676
Lubrication system, description_{11-28-13}....679
Lubrication system, description_{11-28-42}....682
Lubrication system, specifications....685
Lubrication system, valve function....686
Oil cooler, tightening torques....688
Piston cooling system, description....689
23 - FUEL SYSTEM....691
Air in fuel system, checking....691
Cylinder balancing, PC test....695
Feed pressure, PC test....696
Feed pump pressure, checking_{11-18-25}....697
Feed pump pressure, checking_{11-18-53}....699
Fuel feed pump, description....701
Fuel feed pump, specifications_{11-20-02}....703
Fuel feed pump, specifications_{11-20-25}....704
Fuel filter housing, description....705
Fuel filter, description....708
Fuel flow, description....711
Fuel pump, inspecting....715
Fuel system, bleeding air, version 1....720
Fuel system, bleeding air, version 2_{11-15-37}....723
Fuel system, bleeding_{11-16-05}....725
Fuel system, description....727
Fuel system, tightening torques....730
Injection pump, description....736
Injection pump, installing, and setting injection angle....740
Injection pump, removing....744
Injection pump, specifications....750
Injector shut off, manual....751
Injector sleeves, replacing....752
Injectors, changing all....762
Injectors, description....768
Injectors, specifications....770
Overflow valve, checking....771
Stall speed, checking....774
Unit injector, adjusting pretension....777
Unit injector, replacing....781
Unit injectors, description....789
Unit injectors, specifications....792
Water separator....794
25 - INLET & EXHAUST SYSTEM....795
Air cleaner, preheating coil, specifications....795
Air intake and filter....796
By-pass valve (wastegate)_{11-00-13}....797
By-pass valve (wastegate)_{11-00-41}....799
Charge air cooler, replacing....802
Cooling fan motor, charge air cooler, checking_adjusting high rpm....809
Cooling fan motor, charge air cooler, checking_adjusting low rpm....813
Exhaust brake, description....817
Exhaust pressure governor (EPG), description_{11-01-23}....819
Exhaust pressure governor (EPG), description_{11-01-51}....822
Hydraulic cooling fan control, PC test....825
Intercooler (charge-air cooling), general....826
Intercooler, specifications....827
Intercooler....828
Preheating coil, replacing....829
Turbocharger, description....832
Turbocharger, inspecting....835
Turbocharger, replacing....838
Turbocharger, specifications....845
26 - COOLING SYSTEM....846
Coolant pump, reconditioning....846
Coolant pump, replacing_{10-44-52}....853
Coolant pump, replacing_{10-45-28}....865
Coolant, changing_{10-46-43}....872
Coolant, changing_{10-47-10}....876
Cooling fan motor, radiator, checking_adjusting high rpm....880
Cooling fan motor, radiator, checking_adjusting low rpm....884
Cooling fan motor, specifications....888
Cooling system specifications....889
Cooling system, description....891
Cooling system, flushing....892
Cooling system, principle illustrations....897
Cooling system, tightening torques....900
Fan system, description....902
Hydraulic cooling fan control, PC test....903
Radiator, adjusting....904
Radiator, installing....906
Radiator, removing....913
Thermostat, replacing ....919
Thermostat, replacing....925
Thermostat, specifications....931
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....932
30 - GENERAL....933
10F9101, engine-dependent steering pressure, hydraulics_{05-40-10}....933