Complete repair service manual with electrical wiring diagrams for Articulated Haulers A25E Volvo / A25E Volvo 4×4, with technical information to maintain, diagnose, repair, and service like professional mechanics.
Articulated Haulers A25E Volvo / A25E Volvo 4×4 workshop service & repair manual includes:
* 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 4×4 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 4×4…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
12F2601, coolant temperature…682
12F2602, cooling system, regulation current control…684
12F2603, coolant level…689
13F3201, system voltage…690
13F3202, charging monitoring…692
14F3303, delayed stop, engine…694
15F3801, inclination indication…696
17F3801, machine hours…697
17F3802, tachograph…699
17F3803, machine distance…700
17F3804, machine hours, correction…701
17F3805, machine distance, correction…702
17F9501, travelled distance, operating hours and number of cycles…703
18F2201, engine oil pressure…705
18F2202, engine oil level…707
18F2203, engine oil temperature…709
19F3701, bus communication reduced…711
19F3702, bus communication open circuit…712
1F2602, coolant level (EMS)…714
20F2501, pedal request engine brake_retarder…716
20F2503, engine brake, activation…718
20F4201, transmission limitation brake torque application…720
20F4202, retarder activation…722
20F5201, brake lights…724
21F2701, engine On_Off…725
21F2702, starter motor…727
21F2703, stop engine…729
21F3301, start electronics…730
21F3302, stop electronics…732
21F3304, safety stop…734
22F8501, seat belt, check…735
24F9901, theft protection…737
25F9101 Warning, dump lever not in float position…739
25F9102 Warning, dump lever not in hold position…740
25F9501 Warning, body up…742
25F9502, work cycle start…744
26F3601, windshield washer…745
26F3603, windshield wiper interval…746
28F2701, engine speed…747
28F2702, idle speed…749
28F2703, engine speed monitoring…750
28F4201 transmission overspeeding…752
28F4301, vehicle speed_distance…754
28F4302 Exceeded speed limit…756
29F4201, oil temperature, display…757
2F4204, control of transmission…758
2F4206, turbine speed, transmission…762
2F4209, oil temperature in transmission…764
2F4210, lubrication oil pressure in transmission…766
2F4211, output speed, transmission…768
2F4214, slipping discs, lock-up…770
2F4221, oil pressure control…772
30F4201, back-up alarm and back-up light…774
30F4202, gearshift selector…775
30F4203, shift lock-out (hold)…777
30F4204, start 2nd gear…779
31F3601, buzzer central warning…780
31F3801, orange central warning_{08-54-39}…781
31F3801, orange central warning_{08-55-02}…782
31F3802, red central warning…783
31F3803, red extra central warning…784
31F3804, external activation of red central warning…785
31F3805, external activation of orange central warning…786
31F3806, external activation of buzzer central warning…787
32F3807, information display unit, display outside temperature…788
32F5201, Display unit, brake cooling oil temperature…789
35F9901 Parameter list…790
35F9901 Parameters, MO10 module oils, pressures…792
35F9901 Parameters, MO11 module Automatic Traction Control (ATC)…794
35F9901 Parameters, MO14 module delayed stop…796
35F9901 Parameters, MO18 module engine oil…797
35F9901 Parameters, MO20 module retardation…798
35F9901 Parameters, MO22 module operator's seat…799
35F9901 Parameters, MO24 module theft protection…800
35F9901 Parameters, MO25 module dump lever…801
35F9901 Parameters, MO26 module wipers_washing windshield…802
35F9901 Parameters, MO28 module speeds (rpm)…803
35F9901 Parameters, MO3 module acceleration…805
35F9901 Parameters, MO30 module gear selector…807
35F9901 Parameters, MO31 module warnings…808
35F9901 Parameters, MO37 module service…809
35F9901 Parameters, MO4 module power take-off…811
35F9901 Parameters, MO6 module fuel…812
35F9901 Parameters, MO8 module display setting…813
35F9901 Parameters, MO9 module inlet system…815
37F3801, service interval machine…816
37F3802, service interval engine oil…818
37F3803, service interval transmission oil…820
3F2701, engine acceleration, applied throttle value…822
3F8301, door open…823
4F2701, operating speed engine…825
5F5201, output pressure brakes…828
5F5202, brake pressure in accumulator…830
5F5501, parking brake…832
5F5601, stroke warning…835
5F5901, load and dump brake…836
6F2301, main fuel filter…838
6F2302, fuel level in tank…839
6F2303, fuel consumption…841
6F2304, water in fuel…843
6F2305, fuel pressure…844
8F3801, language and unit selection…845
8F3802, date and time…847
8F3803, display unit lighting_display…849
8F3804, instrument lighting…851
8F3805, Inactive warnings_error codes, reset…852
8F3806, Inactive warnings_error codes, reset…853
9F2501, preheating induction air…855
9F2504, air filter…857
Component descriptions…858
Control units, voltage supply…862
Data bus system…864
Data links, fault tracing with Oscilloscope…865
Electrical cabling and connectors, checking…875
Electrical system, basic check…880
Electrical system, special instructions for servicing, action when working on machine…881
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator_{09-52-13}…883
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator_{09-52-42}…885
Electrical system, special instructions for servicing, electrical components, batteries…887
Electrical system, special instructions for servicing, electronic components…889
Electrical system, specifications…892
Electronic control system, special tool measuring, E–ECU…894
Electronic control system, special tool measuring, I-ECU…896
Electronic control system, special tool measuring, T-, V- and V2-ECU…898
Electronic control system, special tool measuring, component…899
Electronic control system, special tool measuring, general…901
Electronic control system, special tool measuring, transmission PT…903
Error causes…905
Error code and warning levels…909
Error codes, build-up…912
Error codes, showing…917
Error detection…919
General vehicle electronics…920
HE2501, description and measuring…922
MA2301–MA2306, description and measuring…923
MA2504, description and measuring…925
MA2505, description and measuring…927
MA4201-MA4207, description and measuring…929
MA4601-MA4603, description and measuring…931
MA4604, description and measuring…933
MA5501, description and measuring_{08-13-17}…935
MA5501_MA5502, description and measuring_{08-11-58}…937
MA5901, description and measuring_{08-09-23}…939
MA5901, description and measuring_{08-10-42}…941
MA9101, description and measuring…944
MA9102, description and measuring…946
MID 128 PID 158 Battery voltage, description and measuring…948
MID 128 SID 211 5 V feed to engine sensors 2, description and measuring…950
MID 128 SID 230 IVS, description and measuring…951
MID 128 SID 232 5 V feed to engine sensors 1, description and measuring…953
Machine status hardware_software…954
Measuring symbols, description…955
Measuring, general…959
PWM2501, description and measuring…961
PWM2601_PWM2602, description and measuring…963
PWM4201, description and measuring…965
PWM4202, description and measuring…967
PWM4203, description and measuring…969
PWM4204, description and measuring…971
RE2501, description and measuring…973
RE3704, description and measuring…975
RE3801, description and measuring…977
RExxxx, Relays general, description and measuring…979
SAE J1708 (Information bus)…981
SAE J1708_1587 information link, description and measuring…983
SAE J1939_ CAN-bus (control bus)…985
SAE J1939_CAN control link, description and measuring…987
SE2202, description and measuring…989
SE2203, description and measuring…991
SE2205, description and measuring…993
SE2301, description and measuring…995
SE2302, description and measuring…997
SE2303, description and measuring…999
SE2501, description and measuring…1001
SE2502, description and measuring…1003
SE2507, description and measuring…1005
SE2508, description and measuring…1007
SE2509, description and measuring…1009
SE2601_SE2602, description and measuring…1011
SE2603, description and measuring…1013
SE2606, description and measuring…1015
SE2701, description and measuring…1017
SE2702, description and measuring…1019
SE2703, description and measuring…1021
SE3201, description and measuring…1023
SE3801, description and measuring…1025
SE3802, description and measuring…1027
SE4201, description and measuring…1029
SE4202, description and measuring…1031
SE4203, description and measuring…1033
SE4204, description and measuring…1035
SE4208, description and measuring…1037
SE4212, description and measuring…1039
SE4213, description and measuring…1041
SE4214, description and measuring…1043
SE4307, description and measuring…1045
SE4607, description and measuring…1047
SE5201_SE5202, description and measuring…1049
SE5203_SE5204, description and measuring…1051
SE5501, description and measuring…1053
SE5601-SE5605, description and measuring…1055
SE5901, description and measuring…1057
SE8301, description and measuring…1059
SE8501, description and measuring…1061
SE8502, description and measuring…1063
SE8701, description and measuring…1065
SE9102_SE9103, description and measuring…1067
SE9104, description and measuring…1069
SE9105, description and measuring…1071
SE9501, description and measuring…1073
SW3301, description and measuring…1075
SW3801, description and measuring…1077
SW5501, description and measuring_{06-41-36}…1079
SW5501, description and measuring_{06-42-21}…1081
SW5901, description and measuring…1083
SWxxxx, description and measuring…1085
Service connection and programming connection…1087
Software design…1089
Software versions and ECUs_part number, checking…1092
Software versions and ECUs_part number, general…1095
Software versions and ECUs_part number, list…1097
Troubleshooting strategy…1099
Troubleshooting, general…1101
V2007.3.0, change specification…1102
V2007.4.0, change specification…1103
V2007.5.0, change specification…1104
V2007.6.0, change specification…1105
V2008.1.0, change specification…1106
V2008.3.0_V2008.3.1, change specification…1108
V2008.4.0, change specification…1109
V2009.4.0, change specification…1110
31 – BATTERY…1111
Batteries, replacing…1111
Battery, charging…1113
Battery, description…1115
Battery, specifications…1116
32 – ALTERNATOR; CHARGE REGULATOR…1117
Alternator, description…1117
Alternator, replacing incl function checking…1118
Alternator, specifications…1122
Alternator, tightening torques…1124
33 – STARTING SYSTEM…1126
Cold-start device, specifications…1126
Starter motor, replacing…1127
Starter motor, specification…1130
Starter motor, tightening torques…1132
35 – LIGHTING…1134
Headlights, adjusting…1134
Lighting, specifications…1138
Working lights, description…1140
36 – OTHER ELECTRICAL EQUIPMENT…1141
Connectors, overview…1141
Connectors, position…1148
Control unit, description…1153
I-ECU MID 140 non-programmed, replacing…1155
I-ECU MID 140 pre-programmed, replacing…1159
T-ECU, MID 130, changing non-programmed ECU…1160
T-ECU, MID 130, changing pre-programmed ECU…1165
Tech Tool, programming of machine…1166
V-ECU MID 187 non-programmed, replacing…1168
V-ECU MID 187 pre-programmed, replacing…1178
Windscreen wiper front motor, replacing…1180
Windscreen wiper motor, tightening torques…1193
37 – CABLE; FUSE; RELAY…1194
Components, list and positions…1194
Electrical distribution box, description…1202
Electrical symbols and designations…1206
Explanation of wiring diagrams…1211
Grounding points, frame connections – Image…1214
Grounding points, frame connections…1215
Wiring diagram A01…1217
Wiring diagram A02…1219
Wiring diagram A03…1221
Wiring diagram A04_{06-18-24}…1223
Wiring diagram A04_{06-18-52}…1226
Wiring diagram A05_{06-17-15}…1229
Wiring diagram A05_{06-17-43}…1232
Wiring diagram A06…1235
Wiring diagram A07…1238
Wiring diagram A08…1241
Wiring diagram A09…1244
Wiring diagram A10…1247
Wiring diagram A11_{06-13-11}…1249
Wiring diagram A11_{06-13-39}…1252
Wiring diagram A12…1255
Wiring diagram A13…1258
Wiring diagram A14…1261
Wiring diagram A15…1264
Wiring diagram A16…1267
Wiring diagram A17…1269
Wiring diagram A18…1271
Wiring diagram A19…1273
Wiring diagram A21_{06-07-23}…1275
Wiring diagram A21_{06-07-50}…1277
Wiring diagram A22…1280
Wiring diagram A23…1283
Wiring diagram A24_{06-05-07}…1285
Wiring diagram A24_{06-05-34}…1287
Wiring diagram A25…1290
Wiring diagram A26…1292
Wiring diagram A27…1295
Wiring diagram A28…1297
Wiring diagram A29…1299
Wiring diagram A33…1302
Wiring diagram A34…1303
Wiring diagram A35…1305
Wiring diagrams…1307
38 – INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM…1309
1.0 Setting to zero, service interval machine…1309
1.0.1 Acknowledgement, change of engine oil…1311
1.0.1 Engine oil, monitoring change interval…1313
1.0.2 Acknowledgement, change of transmission oil…1315
1.0.2 Transmission oil, monitoring change interval…1317
1.1_ 1.2 Error code screens, general…1319
1.3_1.4 Saved error codes_warnings…1321
1.3_1.4 Setting to zero, saved error codes_warnings…1323
Axles and brakes…1325
Digital input and output signals…1327
Electrical system…1332
Engine…1337
Group 1, service screens…1340
Hydraulics…1343
Initial display and settings…1344
Instruments and controls, climate control panel…1348
Instruments and controls, control panel…1349
Instruments and controls, left instrument panel…1351
Instruments and controls, main instrument…1353
Instruments and controls, overview…1356
Instruments and controls, right instrument panel…1358
Operating information and service…1360
Service display unit, general…1363
Service display unit, summary…1365
Transmission…1367
Warning screens, cab…1370
39 – MISCELLANEOUS…1372
CareTrack antenna, replacing…1372
CareTrack system, description…1380
Rear view monitor, service menu…1382
4 – POWER TRANSMISSION…1387
40 – GENERAL…1388
Drive axles, capacity…1388
Drivetrain, description…1389
Dropbox, capacities…1391
Hydraulic transmission, capacity…1392
Power transmission, specifications…1393
41 – CLUTCH; TORQUE CONVERTER…1394
Description…1394
Lock-up clutch…1396
42 – TRANSMISSION; HYDRAULIC CONTROL…1397
Checking of main, torque converter and lubricating oil pressure…1397
Checklist, control system, transmission…1401
Component and description…1402
Description, retarder…1405
Description-…1407
Engine and transmission, installing_{05-28-52}…1409
Engine and transmission, removing_{05-29-09}…1410
Gear F1…1411
Gear F2…1412
Gear F3…1413
Gear F4…1414
Gear F5…1415
Gear F6…1416
Hydraulic diagram PT – Image…1418
Hydraulic diagram PT…1419
Hydraulic transmission, specification…1423
Induction sensor for turbine speed, replacing…1424
Planetary gear…1429
Pressure accumulation…1431
Reverse gear R1…1433
Reverse gear R2…1435
Seal for rear output shaft, replacing…1436
Transmission of power…1444
Transmission, clutches and brakes…1446
Transmission, cut-away drawing – Image…1448
Transmission, cut-away drawing…1449
Transmission, installing on a non mounted engine_{05-28-41}…1451
Transmission, installing…1454
Transmission, removing from a non mounted engine_{05-29-32}…1471
Transmission, removing…1476
Transmission, tightening torques…1498
43 – GEARBOX…1501
Checking and adjusting the longitudinal differential lock…1501
Differential lock dropbox sender unit, adjustment…1502
Dropbox seal for front otput shaft, replacing…1507
Dropbox seal for rear output shaft, replacing…1516
Dropbox, component location…1523
Dropbox, installing…1530
Dropbox, removing…1536
Dropbox, specifications…1543
Dropbox, tightening torque…1544
Rotation speed sensor, replacing…1546
Transfer gearbox, description…1550
45 – PROPELLER SHAFT…1553
Intermediate shaft and_or bearing, replacing (in frame joint)…1553
Intermediate shaft, cut-away view…1577
Propeller shaft, tightening torque…1580
Propeller shaft…1582
46 – FRONT AXLE; REAR AXLE…1583
Axles, tightening torques…1583
Centre gear , removing and installing…1587
Centre gear, replacing…1606
Drive shafts, specifications_{05-15-24}…1623
Drive shafts, specifications_{05-15-53}…1624
Final drive, 1st bogie axle, cut-away view…1625
Final drive, front axle and 2nd bogie axle, cut-away view…1627
Front and rear axles, specifications_{05-15-37}…1629
Front and rear axles, specifications_{05-16-07}…1631
Hub end AH56E–AH56G, AH64D–AH64F, cut-away view…1633
Hub reduction, installing…1637
Hub reduction, removing…1638
Oil and seals AH64D-AH64F…1639
Spindle, replacing one side…1641
Transverse differential lock_axle, checking and adjusting…1666
48 – POWER TAKE OFF…1670
Power take-off, between engine and gearbox, reconditioning…1670
Power take-off, tightening torque…1706
49 – MISCELLANEOUS…1708
Oil cooler, replacing…1708
Oil cooler, tightening torques…1711
5 – BRAKE…1713
50 – GENERAL…1714
A30D, cut-away view…1714
Brake system, specifications…1718
Compressed air diagram – Image…1720
Compressed air diagram_{04-52-04}…1722
Compressed air diagram_{04-52-18}…1726
Compressed air-hydraulic brake system…1730
Introduction…1732
Oil and seals…1734
Pressure check connections, description-…1737
51 – WHEEL BRAKE…1739
Brake calliper removed, reconditioning…1739
Brake calliper, replacing one…1743
Brake disc, replacing one…1744
Brake pads, replacing (one wheel, front axle)…1745
Service brake, specifications…1746
52 – HYDRAULIC BRAKE SYSTEM…1747
Brake booster, overview illustration…1747
55 – PARKING BRAKE…1749
Load and Dump brake function, checking…1749
Load and dump brake working pressure, checking and adjusting…1750
Parking brake , replacing brake caliper…1752
Parking brake brake pads, replacing…1764
Parking brake function, checking…1771
Parking brake, description…1773
Parking brake, function description_{04-47-09}…1774
Parking brake, function description_{04-47-27}…1777
Parking brake, manually releasing…1780
Parking brake, replacing brake disc…1782
Parking brake, replacing…1793
Parking brake, specifications…1794
Parking brake, tightening torque…1796
Spring brake cylinder, replacing…1798
56 – COMPRESSED-AIR BRAKE…1808
Brake system, bleeding…1808
Brake system, relieve pressure…1812
Compressed air brake, function check…1814
Compressor, replacing…1819
Cut-in pressure, adjusting…1830
Cut-in pressure, checking…1832
6 – STEERING…1835
60 – GENERAL…1836
Steering system, description…1836
Steering system, specifications…1838
Troubleshooting tips…1839
64 – STEERING…1841
Damping cylinder seal, changing…1841
Damping cylinder, checking spring force…1846
Damping cylinder, specification…1850
Damping cylinder…1851
Lever bracket steering bearing, replacing…1853
Pressure build-up, engine-dependent pumps, description-…1875
Secondary steering hydraulic pump, installing…1878
Secondary steering hydraulic pump, removing…1883
Secondary steering working and stand-by pressure, adjusting…1886
Steering angle, checking and adjusting…1890
Steering cylinder bearings, replacing_{04-25-19}…1892
Steering cylinder bearings, replacing_{04-25-45}…1899
Steering cylinder removed, reconditioning excl replacing bearings…1905
Steering cylinder, description…1912
Steering cylinder, installing…1914
Steering cylinder, removing…1920
Steering cylinder, specifications…1924
Steering gear, checking and adjusting…1925
Steering gear, replacing…1927
Steering gear, specifications…1937
Steering linkage, checking and adjusting…1939
Steering linkage, tightening torque…1943
Steering times, checking and adjusting…1945
Steering valve neutral position, checking and adjusting…1947
7 – FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT…1951
70 – GENERAL…1952
Description…1952
71 – FRAME…1953
Protective plate, installing…1953
Protective plate, removing…1963
Tractor unit frame…1974
72 – SUSPENSION…1976
Suspension, description…1976
74 – FRAME LINK…1977
Frame joint, changing bearing, machine separated (on load unit frame)…1977
Frame joint, separating machine…1981
Frame joint, tightening torque…2002
Hitch, specifications…2004
Steering joint, replacing bearings…2012
77 – WHEELS; TRACKS; TYRE; HUB; DRUM…2030
Wheel, installing…2030
Wheel, removing_{04-11-09}…2033
Wheel, removing_{04-11-24}…2037
Wheel, tightening torque…2041
8 – MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE…2043
81 – CAB, NAKED; CANOPY…2044
Cab, lifting points…2044
Instructions for drilling in ROPS structure…2047
82 – ENGINE HOOD; MUDGUARD; FOOT STEP…2051
Electric hood pump, changing…2051
Engine hood, installing…2055
Engine hood, removing…2058
Hydraulic diagram, hood opening – Image…2061
Hydraulic diagram, hood opening…2062
83 – DOORS; HATCH; COVER PLATE, (all)…2064
Cab door, installing door catch…2064
Cab door, removing door catch…2066
Door lock, replacing…2069
Door, replacing…2073
84 – TRIM PART; OUTSIDE; GLASS; SEALING MOULDING…2076
Side window, replacing…2076
Windows, general…2080
Windscreen, replacing…2082
85 – CAB INTERIOR; UPHOLSTERY…2090
Air suspension for operator´s seat, changing…2090
Air suspension operator's seat, adjusting-…2093
Air suspension operator's seat, adjusting…2095
Operator's seat, installing…2097
Operator's seat, removing_{04-01-32}…2098
Operator's seat, removing_{04-01-42}…2101
87 – AIR CONDITIONING UNIT…2102
AC system, specifications…2102
Air conditioning AC, basic principles…2104
Air conditioning unit, operation…2106
Air-conditioning, component location…2109
Checking for leaks with inspection light…2110
Condenser, replacing incl draining and filling…2112
Cooling unit, performance test…2116
Evaporator, replacing incl draining and filling…2118
Fan motor, replacing…2128
Heat control valve, replacing…2132
Heat control, replacing…2136
Heater core, replacing…2138
Personal competence and accreditation-[5822]…2151
Personal competence and accreditation…2152
Receiver, replacing incl draining and filling…2154
Refrigerant, draining…2158
Refrigerant, filling incl vacuum pumping…2159
Repair instructions…2160
Safety when working with air-conditioning refrigerant…2162
Thermostat, replacing…2164
Troubleshooting, air conditioning unit (AC)…2167
Wiring diagram A23 – Image…2169
Wiring diagram A23…2171
9 – HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS…2173
90 – GENERAL…2174
Hydraulic and servo systems, description…2174
Hydraulic components, cleanliness when handling…2175
Hydraulic components, storing and transporting…2178
Hydraulic oil, description…2180
Hydraulic oil, storing and handling…2182
Hydraulic system, bleeding…2184
Hydraulic system, description_{03-52-27}…2185
Hydraulic system, description_{03-52-39}…2187
Hydraulic system, relieve pressure…2188
Hydraulic system, repair of hydraulic components in workshop…2190
Hydraulic system, specification…2192
Pressure build-up, engine-dependent pumps, description…2193
Troubleshooting tips…2196
Vacuum pump, connection…2198
Vacuum pump, disconnection…2201
91 – WORKING HYDRAULIC; SERVO HYDRAULICS…2202
Dump lever, changing…2202
Dump lever, description…2207
Dump lever, specifications…2211
Dumping lever, checking pressure…2212
Hydraulic oil tank, description…2216
Hydraulic pump (removed), changing shaft seal…2218
Hydraulic pump, description…2221
Hydraulic pump, max working pressure, checking and adjusting…2224
Hydraulic pump, standby pressure, checking and adjusting…2229
Hydraulic pumps, specifications…2233
Hydraulic system, capacities…2235
Hydraulic system, work instructions…2236
Non-return valve function in steering and dumping valve_{03-47-18}…2238
Non-return valve function in steering and dumping valve_{03-47-28}…2239
Pressure check connections, description…2240
Pump regulator, checking…2243
Pump, installing…2247
Pump, removing…2250
Steering and dumping valve, description…2253
Steering and dumping valve, removed, reconditioning_{03-45-44}…2257
Steering and dumping valve, removed, reconditioning_{03-46-17}…2276
Steering and dumping valve, specifications…2295
Steering and dumping valve, tightening torques…2296
Steering and tipping valve, installing…2298
Steering and tipping valve, removing…2302
Torque limiter, description…2305
Torque limiting valve, checking and adjusting…2306
Working pumps, checking…2309
95 – LOAD CARRIER…2311
Body angle sensor, adjusting…2311
Cylinder, rear flap, gas pressure, checking and adjusting…2312
Dump body alternative, lowering…2316
Dump body joint, changing tipping bearing…2318
Dump body, adjusting against frame…2325
Hoist cylinder bearing, changing_{03-39-30}…2332
Hoist cylinder bearing, changing_{03-39-47}…2337
Hoist cylinder removed, reconditioning…2343
Hoist cylinder, description…2352
Hoist cylinder, installing…2354
Hoist cylinder, removing…2358
99 – MISCELLANEOUS…2362
Explanations to hydraulic diagram…2362
Hydraulic diagram, complete – Image…2371
Hydraulic diagram, complete…2372
Hydraulic pressure, specifications…2375
Steering and dumping valve, overview illustration…2377
Articulated Haulers A25E Volvo / A25E Volvo 4×4 Service Repair Manual
