Volvo R100E Rigid Haulers Workshop Repair Service Manual PDF Wiring Diagrams - MVLVCONR100E.zip

A full service manual, complete with Electrical Wiring Diagrams, for the Volvo R100E Rigid Haulers — packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.

The workshop service and repair manual for Volvo R100E Rigid Haulers 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.

Volvo R100E Rigid Haulers Repair & Service Manual.pdf

PRODUCT DETAILS:

Total Pages: 3,312 pages

File Format: PDF (Windows & Mac & Linux)

Language: English

TABLE OF CONTENTS

0 - Foreword...2

0 - GENERAL...3

00 - DESCRIPTION; COMPLETE MACHINE...4

Complete machine; descriptions_{48-32}...5

Complete machine; descriptions_{48-22}...7

Information and warning decals_{48-04}...10

Information and warning decals_{45-15}...16

Product identification plates...23

03 - SPECIFICATIONS...26

Standard tightening torques...27

Tyre equipment and recommended tyre pressures...30

Weights_{33-30}...32

Weights_{33-20}...34

07 - STANDARD TIME...36

Operation numbers for additional work...37

08 - TOOL...39

E-9000...40

09 - MISCELLANEOUS...43

Basic checks...44

Collection of basic data...45

Troubleshooting strategy_30-32...47

Engine; basic check_{30-15}...48

Engine; basic check_{29-50}...53

Electrical system; basic check_{29-17}...58

Electrical system; basic check_{26-59}...61

Transmission; basic check...64

Power transmission; basic check_{20-20}...65

Power transmission; basic check_{20-07}...68

Steering and hydraulics; basic check_{19-47}...71

Steering and hydraulics; basic check_{19-34}...73

Brake system; basic check_{19-15}...75

Brake system; basic check_{18-57}...79

Parking brake; basic check...83

1 - STANDARD PARTS; SERVICE...85

16 - LUBRICANT; FUEL; OTHER FLUID...86

Recommended lubricants...87

Grease...90

Hydraulic oil...91

Coolant...92

Exhaust heated dump body...93

Purpose of fluid analysis...94

Fluid analysis; tools...98

Fluid analysis; sampling instructions...105

Fluid analysis; administration procedures...112

Fluid analysis; sampling points_{15-10}...116

Fluid analysis; sampling points_{14-57}...119

Recommendations for fluid sampling intervals...122

Engine oil; sampling...123

Brake cooling oil; sampling...126

Hydraulic oil; sampling_{13-24}...130

Hydraulic oil; sampling_{13-01}...134

Transmission oil; sampling...138

Axle oil; sampling...142

Fuel; sampling...145

AdBlue®_DEF; sampling...150

Coolant; sampling...155

17 - SERVICE...159

Safety when servicing...163

Service...165

Service points_{08-30}...166

Service points_{08-19}...168

Arrival Inspection; according to Inspection Programme...170

Delivery Inspection; according to Inspection Programme...171

Maintenance of Stored Machines; according to Inspection Programme...172

Maintenance service; first 10 hours...173

Maintenance service; first 150 hours...174

Maintenance service; every 10 hours...175

Maintenance service; every 50 hours...176

Maintenance service; every 250 hours_{57-01}...177

Maintenance service; every 250 hours_{56-51}...179

Maintenance service; every 500 hours_{56-34}...181

Maintenance service; every 500 hours_{56-23}...183

Maintenance service; every 1000 hours_{56-06}...185

Maintenance service; every 1000 hours_{55-56}...187

Maintenance service; every 1500 hours_{55-39}...189

Maintenance service; every 1500 hours_{55-29}...191

Maintenance service; every 2000 hours_{55-12}...193

Maintenance service; every 2000 hours_{55-01}...196

Maintenance service; every 4000 hours_{54-44}...199

Maintenance service; every 4000 hours_{54-34}...202

Maintenance service; every 6000 hours_{54-17}...205

Maintenance service; every 6000 hours_{54-06}...206

Maintenance service; every 8000 hours...207

Maintenance service; every 10000 hours...208

Service position ...209

Lubrication; every 50 hours...212

Lubrication; every 500 hours...215

Lubrication; every 1500 hours...217

Basic service...218

Engine breather; checking_{51-55}...220

Engine breather; checking_{51-44}...222

Drive belts; checking_{51-27}...224

Drive belts; checking_{51-14}...227

Valves; adjusting...230

Engine oil and filter; changing_{50-43}...231

Engine oil and filter; changing_{50-30}...234

Water separator; checking_{50-10}...237

Water separator; checking_{49-58}...240

Fuel filter; replacing_{49-41}...242

Fuel filter; replacing_{49-29}...244

Fuel prefilter; replacing_{49-11}...246

Fuel prefilter; replacing_{48-58}...250

Fuel tank breather; checking_{48-39}...254

Fuel tank breather; checking_{48-28}...256

Fuel tank filler neck; checking_{48-10}...258

Fuel tank filler neck; checking_{47-59}...260

Ether cylinder; checking ...262

Fuel tank; cleaning_{47-19}...265

Fuel tank; cleaning_{47-01}...269

AdBlue®_DEF pump unit filter; replacing...273

AdBlue®_DEF inline filter; replacing_...277

AdBlue®_DEF filler neck; checking_...280

AdBlue®_DEF tank breather; checking_...283

NOx sensor; replacing ...285

Air cleaner restriction indicator; checking...288

Engine air cleaner primary filter; replacing...289

Engine air cleaner secondary filter; replacing...292

Coolant level; checking...295

Coolant; changing...297

Coolant mixture; checking...300

Engine fan hub; checking_{43-15}...302

Engine fan hub; checking_{43-04}...304

Cooling fan; checking...306

Cooling fan; inspecting_{42-34}...307

Cooling fan; inspecting_{42-23}...309

Coolant filter; replacing_{42-05}...311

Coolant filter; replacing_{41-51}...313

Engine fan idler (pivot arm); lubricating_{41-31}...315

Engine fan idler (pivot arm); lubricating_{41-20}...317

Transmission oil; changing...319

Transmission breather; checking...322

Transmission oil filter; replacing...323

Transmission breather filter; replacing...325

Planetary drive oil level; checking...327

Planetary drive oil; changing...328

Differential oil level; checking...330

Differential breather; checking...331

Differential oil; changing...333

Axle hub oil; changing...334

Power Take Off (PTO) engine breather; checking...336

Power Take Off (PTO) engine oil; changing...338

Brake disc wear; measuring...340

Brake cooling filter; replacing...343

Steering pressure filter; replacing...346

Tyre wear and air pressure; checking...350

Wheel nuts torque; checking...352

Tightening torque of bolts; checking...353

Railings; platforms and steps; checking...355

Air conditioner main filter; replacing...356

Cab main filter; cleaning...358

Cab main filter; replacing...360

Air conditioning compressor oil; changing...362

Hydraulic oil filter restriction indicator; checking...366

Hydraulic oil level; checking...368

Hydraulic oil; changing...369

Hydraulic tank suction magnetic filters; checking...371

Hydraulic oil tank breather; checking...374

Hydraulic oil tank breather filter; replacing...375

Hydraulic tank sediment; draining...377

Hydraulic pressure; checking_{32-04}...379

Hydraulic pressure; checking_{31-53}...382

Accumulators; checking_{31-35}...385

Accumulators; checking_{31-18}...390

Starting with booster batteries...394

Recovering and towing...397

Transporting the machine...402

19 - GENERAL...405

Personal protective equipment...406

Service position...408

Safety concerns everybody!...411

CE-marking; EMC-directive...412

Safety when handling the machine...413

Fire prevention measures_{27-25}...416

Fire prevention measures_{27-09}...419

Check list after fire or heat exposure...422

Working on the electrical system of the machine_{26-16}...423

Working on the electrical system of the machine_{25-56}...426

Safety when handling accumulators...429

Safety when handling oil and fuel...430

Safety when using lifting equipment...431

Safety when lifting and supporting the machine...432

Safety during electric welding_{24-23}...433

Safety during electric welding_{24-12}...435

Environment...437

Environmental handling for the future...438

Environmentally safe handling...439

Environmentally hazardous fluids...441

Health hazards with paint; plastics and rubber...442

Working in environmentally contaminated areas...444

Decontamination...445

Waste handling...446

2 - ENGINE WITH MOUNTING AND EQUIPMENT...447

20 - GENERAL...448

Engine; description_{20-32}...449

Engine; description_{20-20}...452

Engine refill capacities; specifications_{20-02}...456

Engine refill capacities; specifications_{19-52}...457

Engine electric components; component locations_{19-35}...458

Engine electric components; component locations_{19-23}...461

21 - ENGINE...464

Engine; specifications_{18-14}...465

Engine; specifications_{18-04}...466

Engine; removing_{17-46}...467

Engine; removing_{16-52}...483

Engine; installing_{13-18}...505

Engine; installing__{12-54}...522

Engine; component locations_{08-55}...544

Engine; component locations_{08-43}...547

Engine; tightening torques_{08-25}...550

Engine; tightening torques_{08-15}...551

Valve system; specifications_07-59...553

Valve system; specifications...554

Vibration damper; removing_{07-32}...555

Vibration damper; removing_{07-20}...557

Vibration damper; installing_{06-24}...561

Vibration damper; installing_{06-13}...563

Engine mounting; tightening torques...567

Engine mounts; replacing_{05-21}...568

Engine mounts; replacing_{05-04}...572

22 - LUBRICATING SYSTEM...576

Lubrication system; specifications_{03-51}...577

Lubrication system; specifications_{03-41}...578

Lubrication system; tightening torques...579

Lubrication system; description...580

Lubrication system; component locations_{02-53}...581

Lubrication system; component locations_{02-50}...583

23 - FUEL SYSTEM...585

Fuel system; specifications_{01-35}...586

Fuel system; specifications_{01-24}...587

Fuel system; tightening torques...588

Fuel system; description_{00-52}...589

Fuel system; description_{00-41}...592

Fuel system; component locations_{00-11}...595

Fuel system; component locations_{00-12}...597

Fuel filters; replacing_{59-25}...599

Fuel filters; replacing_{59-13}...602

Fuel tank; specifications_{58-29}...605

Fuel tank; specifications_{58-19}...606

Fuel level; description_{58-02}...607

Fuel level; description_{57-51}...609

Fuel shut-off valve; replacing_{57-32}...611

Fuel shut-off valve; replacing_{57-19}...613

Fuel tank breather cap; replacing_{57-00}...616

Fuel tank breather cap; replacing_{56-48}...618

Fuel tank level sensor; replacing_{56-28}...620

Fuel tank level sensor; replacing_{56-13}...624

Fuel tank sight gauge; replacing_{55-54}...627

Fuel tank sight gauge; replacing_{55-42}...629

Fuel tank; removing_{55-23}...631

Fuel tank; removing_{55-09}...636

Fuel tank; installing_{54-48}...641

Fuel tank; installing_{54-34}...645

Fuel tank; tightening torques_{54-14}...649

Fuel tank; tightening torques_{54-03}...650

Fuel lines; replacing_{53-46}...651

Fuel lines; replacing_{53-33}...654

25 - INLET & EXHAUST SYSTEM...656

Inlet and exhaust system; specifications...658

Inlet and exhaust system; tightening torques_{52-07}...659

Inlet and exhaust system; tightening torques_{51-55}...662

Inlet and exhaust system; description_{51-37}...665

Inlet and exhaust system; description_{51-27}...667

Inlet and exhaust system; component locations_{51-10}...669

Inlet and exhaust system; component locations_{50-59}...671

Exhaust pipe; replacing...673

Flexible pipe; replacing...676

Exhaust pipe; removing...678

Exhaust pipe; installing...699

Flexible pipe; removing...721

Flexible pipe; installing...741

Exhaust aftertreatment system; description...761

Exhaust aftertreatment system; component locations...766

AdBlue®_DEF pump unit; replacing...769

AdBlue®_DEF tank; removing...772

AdBlue®_DEF tank; installing...777

AdBlue®_DEF inline filter; replacing...782

AdBlue®_DEF filler neck; checking...785

AdBlue®_DEF tank; draining...788

NOx sensor; replacing...791

AdBlue®_DEF...794

AdBlue®_DEF pump unit; filter; replacing...802

AdBlue®_DEF tank breather; checking...806

Air cleaner; removing_{35-04}...808

Air cleaner; removing_{30-01}...811