Volvo A25C Articulated Hauler Workshop Repair Service Manual PDF - MVOLCOA25C.zip
A full workshop service manual featuring complete electrical wiring schematics for the Articulated Haulers A25C Volvo / A25C Volvo BM / A25C Volvo 4x4 / A25C Volvo 4x4 BM, packed with technical data that lets you maintain, troubleshoot, and overhaul the machine just as skilled technicians would.
The workshop service & repair manual for Articulated Haulers A25C Volvo / A25C Volvo BM / A25C Volvo 4x4 / A25C Volvo 4x4 BM 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
PRODUCT DETAILS:
Pages: 1,170
File Format: PDF (Windows & Mac & Linux)
Language: English
...
TABLE OF CONTENTS
0 - Foreword.......2
0 - GENERAL.......3
00 - DESCRIPTION; COMPLETE MACHINE.......4
Description-[3028].......4
Product identification plates.......5
03 - SPECIFICATIONS.......6
Brakes.......6
Electrical system.......9
Engine.......12
Hydraulic system.......15
Power transmission-.......17
Specifications, capacities-.......21
Specifications, change intervals.......22
Specifications, dimensions.......23
Specifications, tightening torques].......25
Specifications, weights .......36
Steering system.......38
Volvo standard tightening torques.......39
07 - STANDARD TIME.......41
Time Guide.......41
08 - TOOL.......50
Drawings of E-tools that can be made in your own workshop.......50
Recycling station FRS-10GS.......63
Special tools for the drivetrain.......65
1 - STANDARD PARTS, SERVICE.......69
16 - LUBRICANT; FUEL; OTHER FLUID.......70
Brake system, changing brake fluid.......70
Recommended lubricants.......72
17 - SERVICE.......74
Cleanliness, hydraulic systems.......74
Electric welding.......75
Repairs of hydraulic systems.......76
Towing.......77
2 - ENGINE WITH MOUNTING AND EQUIPMENT.......80
21 - ENGINE.......81
Compression check, engine at operating temperature.......81
Description.......84
Engine and transmission, mounting.......85
Engine and transmission, removing.......89
Engine, mounting.......98
Engine, removing.......102
Specifications, capacities-[1855].......110
Specifications, general-[1633].......111
Specifications, general-[1810].......112
Specifications, tightening torques-[1423].......113
Specifications, tightening torques-[1451].......116
Specifications, tightening torques-[1536].......117
Specifications, tightening torques-[1550].......118
Specifications, tightening torques-[1657].......119
Specifications, tightening torques-[1721].......120
Specifications, tightening torques-[1750].......121
Specifications, tightening torques-[1841].......122
Specifications, weights-[1823].......124
Valves, adjusting.......125
22 - LUBRICATING SYSTEM.......127
Lubrication oil pressure, checking.......127
Specifications, general-.......129
Specifications, general-[1304].......130
23 - FUEL SYSTEM.......131
Automatic timing adjuster (alpha adjuster).......131
Automatic timing adjuster, checking.......132
Fuel feed pump, checking feed pressure.......138
Fuel injection pump, changing incl. setting injection timing.......140
Fuel system, bleeding.......146
Idle speed, checking and adjusting.......148
Injection timing TDC, checking and adjusting.......150
Injection timing, checking.......155
Injectors, changing all.......159
Low and high idle speed, checking and adjusting with service display unit.......163
Low emission engines.......166
Specifications, capacities-[1054].......168
Specifications, general-[0643].......169
Specifications, general-[0814].......170
Specifications, general-[1118].......171
Specifications, tightening torques-[0657].......172
Specifications, tightening torques-[0828].......173
Stall speed, checking with service display unit.......174
Stall speed, checking.......176
25 - INLET & EXHAUST SYSTEM.......177
Specifications, general-[0357].......177
Specifications, general-[0422].......178
Specifications, tightening torques-[0446].......179
26 - COOLING SYSTEM.......180
Coolant filter, changing-[0236].......180
Coolant filter, changing.......182
Coolant, changing.......184
Description-[0327].......187
Fan motor, changing piston rings.......191
Hydraulic motor for fan, alternatively hydraulic pump, checking internal leakage.......197
Radiator fan drive, checking function of motor.......199
Radiator fan drive, general description.......201
Radiator fan motor, adjusting speed.......203
Radiator, changing.......205
Specifications, capacities-[0306].......207
Specifications, general-[0250].......208
Specifications, general-[5932].......209
Thermostat valve (removed), reconditioning.......211
Thermostat valve, checking function.......213
Thermostat valve, description.......214
27 - ENGINE CONTROL.......215
Throttle pedal, anti-throttle cylinder, adjusting.......215
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......217
30 - GENERAL.......218
Description-[5746].......218
Electrical symbols.......219
Fuses.......223
Special instructions for servicing the electrical system.......238
Specifications, general-[5619].......239
31 - BATTERY.......240
Charging of batteries.......240
Specifications, general-[5535].......241
32 - ALTERNATOR; CHARGE REGULATOR.......242
Alternator, changing.......242
Charging, checking in machine (multimeter).......244
Specifications, general-[5410].......249
Specifications, general-[5424].......250
33 - STARTING SYSTEM.......251
Specifications, general-[5342].......251
Starter motor, changing.......252
35 - LIGHTING.......255
Headlight, complete, changing 1 headlight incl. adjusting alignment.......255
Headlights, adjusting against wall or fender.......256
Specifications, general-[5243].......257
37 - CABLE; FUSE; RELAY.......258
A25C 4x4 turn-around wheels (serial no. –12483).......258
Circuit 14–36-[5024].......260
Circuit 14–36.......264
Circuit 37a–37e-[4909].......268
Circuit 37a–37e.......271
Circuit 37f–37I-[4840].......274
Circuit 37f–37I.......278
Circuit 38–53A-[4800].......282
Circuit 38–53A.......285
Circuit 53B–75-[4722].......289
Circuit 53B–75.......293
Circuit 66 and 77-[4648].......297
Circuit 66 and 77.......300
Circuit 76–89-[4610].......303
Circuit 76–89.......307
Circuit 7–13-[5101].......311
Circuit 7–13.......315
Circuit 90–91.......319
Circuit 90–93.......322
Circuit 94–98.......325
Circuit board, right electrical distribution box-[3248].......328
Circuit board, right electrical distribution box.......329
Circuit index.......330
Code legend for connectors-[4111].......333
Code legend for connectors.......410
Codes in wiring diagrams.......489
Explanations of wiring diagrams.......490
Fuses, left electrical distribution box-[3210].......492
Fuses, left electrical distribution box.......494
Fuses, right electrical distribution box-[3142].......496
Fuses, right electrical distribution box.......499
Instrument panel, (serial no. 11101–, BR 70301–, US 66 61401–, 44 68201–).......503
Instrument panel, (serial no. –11100, BR –70300, US 66 –61400, 44 –68200).......505
Other fuses.......507
Relays, left electrical distribution box-[3038].......509
Relays, left electrical distribution box.......511
Relays, right electrical distribution box-[3010].......514
Relays, right electrical distribution box.......516
Specifications, general-[2936].......519
Template for pin numbers connector X1_A1.......520
Wiring diagrams (serial no. –11100, BR –70300, US 66 –61400, 44 –68200) Circuit 0–6.......522
Wiring diagrams(serial no. 11101–, BR 70301–,.......525
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......527
Connection.......527
Contronic Information Display Unit.......528
Contronic service display unit.......530
ECU, reading off with measuring instrument.......532
Information display unit, summary.......534
Information on the information display unit.......535
Information on the service display unit-[2413].......540
Information on the service display unit.......552
Load sensor, adjusting.......561
Load sensor, checking electric circuits.......563
Measuring instrument, summary.......565
Service display unit, summary.......566
Specifications, general-[2622].......567
Specifications, general-[2920].......568
Speedometer, changing-[2857].......569
Speedometer, changing.......571
Speedometer, electric, calibrating.......573
Speedometer, electronic, description.......575
Speedometer, electronic.......579
Using the service display unit.......584
4 - POWER TRANSMISSION.......585
40 - GENERAL.......586
Description-[2125].......586
Power transmission.......588
41 - CLUTCH; TORQUE CONVERTER.......589
Specifications, tightening torques-[2043].......589
42 - TRANSMISSION; HYDRAULIC CONTROL.......590
Control system, changing.......590
Diagnosis using error codes on service display unit.......594
Functional description, transmission.......596
Gearshift selector, checking.......597
Hydraulic diagram, transmission with retarder-[1950].......599
Hydraulic diagram, transmission with retarder.......602
Hydraulic transmission, checking oil pressure.......605
Inductive sensor for output shaft, changing.......609
Inductive sensor for turbine speed, changing.......612
Oil cooler, changing.......617
Safety functions.......620
Seal for rear output shaft, changing.......621
Solenoids, checking resistance.......625
Specifications, capacities-[1446].......627
Specifications, general-[1420].......628
Specifications, general-[1913].......629
Specifications, weights-[1433].......630
Transmission PT1051 – cut-away drawing.......631
Transmission PT1051, general description.......632
Transmission functions, checking instructions for connector X1_A1.......633
Transmission, general troubleshooting.......638
Transmission, mounting(downward).......639
Transmission, removing and mounting (together with engine).......642
Transmission, removing and mounting.......649
Transmission, removing(downward).......652
Troubleshooting chart, transmission.......659
Troubleshooting chart.......661
Troubleshooting outside the control unit in connector X1_A1.......666
Troubleshooting.......668
Wiring diagram, transmission electronics, circuit 37a-I.......669
43 - GEARBOX.......672
Dropbox FL 652 C, general description.......672
Dropbox FL652C.......673
Dropbox, adjusting high and low range.......674
Dropbox, changing compressed air cylinder for high and low range.......678
Dropbox, changing seal for front.......680
Dropbox, changing seal for input shaft.......683
Dropbox, changing seal for rear.......686
Dropbox, mounting.......689
Dropbox, removing.......691
Longitudinal differential lock, adjusting engagement.......696
Specifications, capacities-[0949].......700
Specifications, general-[0908].......701
Specifications, tightening torques-[0936].......702
Specifications, weights-[0921].......703
45 - PROPELLER SHAFT.......704
Intermediate propeller shaft and_or bearing, changing (in frame joint).......704
Propeller shaft between transmission and.......712
Propeller shaft for front bogie axle, changing.......715
Propeller shaft for rear bogie axle, changing.......717
Propeller shaft in frame joint, changing.......719
Propeller shaft, front output shaft on dropbox, changing.......720
Specifications, tightening torques-[0837].......721
46 - FRONT AXLE; REAR AXLE.......723
Dog clutch 66, checking and adjusting.......723
Drive axles AH54 and AH56H.......727
Final drive 66 output shaft, changing.......728
Front axle complete, removing.......732
Hub, changing seals (one side).......736
Specifications, capacities-[0530].......750
Specifications, general-[0314].......751
Specifications, general-[0447].......752
Specifications, tightening torques-[0517].......754
Specifications, weights-[0501].......756
Transverse differential lock, adjusting.......757
48 - POWER TAKE OFF.......761
Flywheel housing (rear engine transmission).......761
Power take-off in flywheel housing, changing.......762
Power take-off in flywheel housing, reconditioning.......764
Specifications, general-[0121].......773
Specifications, general-[0227].......774
5 - BRAKE.......775
50 - GENERAL.......776
Description-[5516].......776
Specifications, general-[5401].......778
51 - WHEEL BRAKE.......779
Brake caliper, changing (per caliper).......779
Brake caliper, reconditioning.......783
Brake disc for service brake, checking.......786