Volvo A25D Dump Truck Service and Repair Manual PDF

Volvo A25D Dump Truck Service and Repair Manual PDF

Size: 32.49 MB
Language: English
Make: Volvo
Machine: Dump Truck
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo A25D
Page: 2153 Pages

Detail Contents:
1 Volvo A25D
1F2602, coolant level (EMS)
4-pin DIN-connectors, remounting
88830051 User Instruction
A25D, A25D 4×4, A30D, A35D, A40D, T450D
AC system, specifications
AC, time relay
Action to be taken in case of abnormal lubricating oil consumption
A-frame bushing, front on load unit, changing
A-frame bushing, rear on load unit, changing
A–frame
Air cleaner, preheating coil, specifications
Air conditioning AC, basic principles
Air conditioning unit, operation
Air in fuel system, checking
Air intake and filter
Air suspension operator’s seat, adjusting
Air-conditioning, component location
Alternative lubricants for axles with wet brakes
Alternator, replacing incl function check 1
Alternator, replacing incl function check
Alternator, specifications 1
Alternator, specifications 2
Alternator, tightening torques
Amendment of Service Manual, D10B
Appointment and distribution of responsibility
A-stay, new rubber bushing
ATC, description
Automatic transmission lubricants
Auxiliary steering, adjusting working- and stand-by pressure
Auxiliary steering, hydraulic pump, installation
Auxiliary steering, hydraulic pump, removing
Axle suspension, tightening torque
Axles, tightening torques
Basic checks
Batteries, replacing
Battery, specifications
Belt guard, new type
Bogie beam, changing rubber bushing on removed beam
Bogie beam, changing rubber spring, one side (front)
Bogie beam, changing
Brake booster, overview illustration
Brake caliper, replacing one 1
Brake caliper, replacing one
Brake calliper removed, reconditioning
Brake calliper, replacing one
Brake disc, changed minimum thickness
Brake disc, replacing one
Brake pads, replacing (one wheel, first boggie axle)
Brake pads, replacing (one wheel, front axle)
Brake system, basic check
Brake system, bleeding 1
Brake system, bleeding
Brake system, relieve pressure
Brake system, specifications 1
Brake system, specifications 2
By-pass valve (wastegate)
Cab description
Cab door, installing door catch
Cab door, removing door catch
Cab, lifting points
Cabin, specification
Camshaft setting, checking
Camshaft, description
Camshaft, replacing
Capacities
Carbon monoxide in fuel system, check
CareTrack Telematics system
CE marking and declaration of conformity
C-ECU, MID178, changing non-Programd ECU
CE-marking, EMC-directive
Centre gear, removing and fitting
Change of crankshaft seal
Checking and adjusting
Checking for leaks with inspection light
Checking of main, torque converter and lubricating oil pressure
Checklist after a fire or heat exposure
Checklist, control system, transmission
Cleaning of the machine 1
Cleaning of the machine
Cleanliness, brake and hydraulic systems
Cold-start device, specifications
Collection of basic data
Combined control by steering wheel, changing
Component and description
Component position 1, AL3201–31GR1
Component position 2, HE2301–LA3601
Component position 3, LA3602–LC4202
Component position 4, LC4601–MA4207
Component position 5, MA4601–R3502
Component position 6, RC8401–SA4201
Component position 7, SE2202–SE5202
Component position 8, SE5203–SO3901
Component position 9, SW2301–SW3801
Component position 10, SW4201–SW9102
Component position
Compressed air brake, function check
Compressed air diagram-1
Compressed air diagram-2
Compressed air diagram-3
Compressed air drier, service solution
Compressed air-hydraulic brake system
Compression test 1
Compression test
Compressor, changing
Compressor, replacing
Condenser, replacing incl draining and filling
Connector for cooling fan PWM valves
Connectors C01–DY, position
Connectors EA–F50, position
Connectors HE3601–TAILR, position
Control units, voltage supply
Contronic socket, mounting plate
Coolant pump removed, reconditioning
Coolant pump, replacing 1
Coolant pump, replacing 3
Coolant pump, replacing
Coolant with freezing and corrosion protection
Coolant, changing 1
Coolant, changing 3
Coolant, changing
Coolant’s freezing point, check
Cooling fan motor, intercooler, checking adjusting low rpm
Cooling fan motor, intercooler, checking-adjusting high rpm
Cooling fan motor, radiator, checking adjusting high rpm
Cooling fan motor, radiator, checking-adjusting low rpm
Cooling fan motor, specifications
Cooling system specifications
Cooling system, description
Cooling system, flushing
Cooling system, principle illustrations
Cooling system, tightening torques
Cooling unit, performance test
Crankshaft and vibration damper, description
Crankshaft, replacing front oil seal 1
Crankshaft, replacing front oil seal
Crankshaft, replacing rear oil seal
Cylinder block, description
Cylinder head gasket, description
Cylinder head guides
Cylinder head, description
Cylinder liners and pistons, description
D9B and D12D Stage 3, valve adjustment, camshaft marking
Damping cylinder, changing seal
Damping cylinder, checking pre-load
Damping cylinder, specification
Damping cylinder
Data bus system
Data buses, function
Data buses, voltage levels
Dealers retrofitter´s responsibility
Decontamination
Description 1
Description, retarder
Description
Diesel fuels – quality and function
Differential lock longitudinal, adjustment of sender unit
Dimension drawing with dimensions, A25D
Dog-clutch for six-wheel drive (6×6), checking and adjusting
Door lock, replacing
Door lock
Door window, replacing
Door, replacing
Double rocker arm, description
Drainage of engine oil
Drawings of E-tools
Drive axles, capacity
Drive axles, description
Drive shafts, specifications
Drivetrain, description
Dropbox, mounting
Dropbox, removing
Dropbox, specifications
Dropbox, weights
Dump body alternative, lowering 1
Dump body alternative, lowering
Dump body joint, changing tipping bearing
Dump body position indicator, adjusting
Dump body, adjusting against frame
Dump lever, changing 1
Dump lever, changing
Dump lever, description
Dump lever, specifications
E1763
E-2516
E-2519
E-ECU, MID 128, changing non-Programd ECU
Electric hood pump, changing 1
Electric hood pump, changing
Electrical symbols and designations
Electrical system, basic check
Electrical system, special instructions for servicing, actions when working on machine
Electrical system, special instructions for servicing, electrical components, alternator and charging regulator
Electrical system, special instructions for servicing, electrical components, batteries
Electrical system, special instructions for servicing, electronic components
Electrical system, special instructions for servicing, general
Electrical system, specifications
Engine and transmission, mounting, version 1
Engine and transmission, mounting, version
Engine and transmission, removing, version 1
Engine and transmission, removing, version 2
Engine and transmission, removing, version 21
Engine cable harness D9A, cable rail for injectors
Engine hood, installing
Engine hood, removing
Engine mounting rear, changing
Engine oil requirements
Engine oil, altered time for the first oil change
Engine oil, interval between changes
Engine reconditioning
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor, replacing
Engine timing gear, description
Engine transmission, specification
Engine, basic check
Engine, capacities 1
Engine, capacities 2
Engine, description
Engine, general specifications
Engine, identification
Engine, mounting
Engine, removing
Engine, sensor positions
Engine, tightening torques
Engine, weights
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Evaporator, replacing incl draining and filling
Exhaust brake, description
Exhaust pressure governor (EPG), description
Explanation of wiring diagrams
Explanations to hydraulic diagram
Fan motor, replacing 1
Fan motor, replacing
Fan regulator, PWM2601 and PWM2602
Fan system, description
Fan, new type
Feed pump, checking feed pressure 1
Feed pump, checking feed pressure
Feed pump, checking feed pressure2
Final drive, 1st bogie axle, cut-away view
Final drive, front axle and 2nd bogie axle, cut-away view
Final drive, removing and mounting 1
Final drive, removing and mounting
Fire prevention measures
Flywheel housing with power take-off (PTO), mounting on engine out of machine
Flywheel housing with power take-off (PTO), removing from engine out of machine
Flywheel housing, draining hole, drilling
Flywheel, tightening torques
Foot brake valve (pneum), replacing
Frame joint, changing bearing, machine separated (on load unit frame)
Frame joint, separating machine 2
Frame joint, separating the machine 1
Frame joint, tightening torque 1
Frame joint, tightening torque
Frame, specifications tightening torques
Fuel feed pump, description
Fuel feed pump, specifications 1
Fuel feed pump, specifications 2
Fuel filter and water separator replacement interval change 1
Fuel filter and water separator replacement interval change
Fuel filter housing with electrical pump, service solution
Fuel filter housing, description
Fuel filter, description
Fuel flow, description
Fuel pump, inspection
Fuel system, bleeding air, version 1
Fuel system, bleeding air, version 2
Fuel system, description
Gear F1
Gear F2
Gear F3
Gear F4
Gear F5
Gear F6
Gearshift selector, changing
General instructions for controls, replacing.
General maintenance instructions
General vehicle electronics
Grounding points (frame connections)
Headlamp, new light bulb
Headlights, adjusting against wall or screen
Health hazards with paint, plastics and rubber
Heat control valve, replacing
Heat control, replacing
Heater core, replacing
Hexagon stay, replacing
Hitch, specifications 1
Hitch, specifications
Hoist cylinder bearing, changing 1
Hoist cylinder bearing, changing
Hoist cylinder removed, reconditioning
Hoist cylinder, description
Hoist cylinder, installation
Hoist cylinder, removal
Hoist cylinder, specifications
Hub A25D A30D, cut-away view
Hub end AH56E–AH56G, AH64D–AH64F, cut-away view
Hub reduction gear, planet carrier, new design
Hub reduction, installing
Hub seal, new design
Hydraulic and servo systems, description
Hydraulic components, cleanliness when handling
Hydraulic components, storage and transport
Hydraulic diagram PT
Hydraulic diagram, complete 1
Hydraulic diagram, complete 2
Hydraulic diagram, complete 3
Hydraulic diagram, complete 4
Hydraulic diagram, hood opening
Hydraulic oil filter, changing
Hydraulic oil tank, description
Hydraulic oil, description
Hydraulic oil, storing and handling
Hydraulic pressure, specifications
Hydraulic pump (removed), changing shaft seal
Hydraulic pump, checking and adjusting max working pressure 1
Hydraulic pump, checking and adjusting max. pressure,engine dependent working hydraulic pumps
Hydraulic pump, checking and adjusting stand-by pressure, engine dependent working hydraulic pumps
Hydraulic pump, description
Hydraulic pump, replacing 1
Hydraulic pump, replacing
Hydraulic pumps, specifications 1
Hydraulic pumps, specifications 2
Hydraulic system, bleeding 1
Hydraulic system, bleeding
Hydraulic system, capacities
Hydraulic system, description
Hydraulic system, relieve pressure
Hydraulic system, repair of hydraulic components in workshop
Hydraulic system, work instructions
Hydraulic transmission, capacity
Hydraulic transmission, weight
Hydraulics
I-ECU, MID 140, changing non-Programd ECU
I-ECU, MID 140, changing pre-Programd ECU
IL1 IL2 Drop box air leakage on piston, cylinder and sleeve for longitudinal diff
IL1IL2 Drop box air leakage on piston, cylinder and sleeve for longitudinal diff 1
Induction sensor for turbine speed, changing
Information on Bio-diesel fuel (RME-fuel)
Injection pump, description
Injection pump, removing 1
Injection pump, removing
Injection pump, specifications
Injector shut off, manual
Injectors, changing all
Injectors, description
Injectors, replacing copper sleeve in machine
Injectors, specifications
Intercooler (charge-air cooling), general
Intercooler, replacing
Intercooler, specifications
Intercooler
Intermediate shaft A25D A30D, new bearings, seals and grease
Intermediate shaft and-or bearing, changing
Intermediate shaft, cut-away view
Intermittent retarder function, PT1563, 1863
KAB Seat, heater range
Lifting machine
Lifting tool, new marking
Lifting tool, new type
Lighting, specifications
Load and dump brake, working pressure, checking and adjusting
Load unit frame
Lock-up clutch
Lubricant, Biodegradable Hydraulic Fluid
Lubrication and service schedules
Lubrication oil pressure, checking with pressure gauge
Lubrication oil pump and oil cooler, description
Lubrication system, description
Lubrication system, specifications
Lubrication system, valve function
Lubrication, see lubrication chart
Machine status hardware software
Maintenance service, daily
Maintenance service, every 50 hours
Maintenance service, every 250 hours
Maintenance service, every 500 hours
Maintenance service, every 1000 hours
Maintenance service, every 2000 hours
Measuring nipples, new type
Mechanical operator’s seat, adjusting
Mechanical release of parking brake
Messages and information content
MS.Internal.Documents
New belt tensioners
New brake pipes and brake guards
New coolant
New display screen for transmission oil level
New fan installation
New floor panel and floor mat
New fuse FC2, preheating
New haulers, A25D and A30D
New hitch 1
New hitch
New Intercooler Hoses
New keypad
New main fuel filter, D9, D12 and D16
New non-return valve with back-pressure function, MTRV1
New pressure sensors
New resistor for the alternator’s charging circuit
New rubber cloth over the batteries
New seals for steering joint bearings
New sensor for accelerator and retarder pedal
New starter switch
New suspension of hydraulic hoses
New tipping spool, valve block
New tool Electrical repair kit, part No. 11666200
New transmission 1
New transmission
New transmissions
New turbocharger for D9A Tier 2 Step II engine
New Volvo standard for transmission oil
New water trap
New wiper motor
Noise reduction kit
Non-return valve function in steering and dumping valve
Oil analyses
Oil and seals AH56E-AH56G
Oil and seals
Oil cooler, replacing 1
Oil cooler, replacing
Oil cooler, specifications
Oil cooler, tightening torques
Oil jet nozzle eliminated from the D12D and D9B exhaust double rocker arm
Oil leakage from the engine cable harness grommet
Oil level sensor, changing
Oil sump gasket, changing
Oil sump, description
Oil sump, tightening torque
Oil trap, description
Operator’s seat, changing air spring
Operator’s seat, installing
Operator’s seat, removing
Output shaft 6-wheel drive, changing bearing
Overflow valve, checking
Parking brake lever, changing
Parking brake, basic check 1
Parking brake, basic check
Parking brake, description
Parking brake, new brake pads
Parking brake, replacing brake disc
Parking brake, replacing brake pads 1
Parking brake, replacing brake pads
Parking brake, replacing
Parking brake, specifications
Personal competence and accreditation
Pipe for dipstick for transmission
Piston cooling system, description
Planetary gear
Portable refillable O-ring kits
Power take-off suction strainer, cleaning
Power take-off, between engine and gearbox, reconditioning
Power transmission, basic check 1
Power transmission, basic check
Power transmission, specifications
Preheating coil, replacing
Pressure accumulation
Pressure build-up, engine-dependent pumps, description 1
Pressure build-up, engine-dependent pumps, description
Pressure check connections, description 1
Pressure check connections, description
Pressure setting and leak detection
Product development 1
Product development
Product identification plates
Propeller shaft, tightening torque
Propeller shaft
Protecting plate, installation
Protecting plate, removal
PTO, gear shaft assembly update
PTO, o-rings update
Pump regulator, checking
Quality of illustrations in technical reports
Radiator, adjusting
Radiator, installation
Radiator, removal
Rear window pane, replacing
Receiver, replacing incl draining and filling
Recommended lubricants
Recovering and towing 1
Recovering and towing
Refrigerant for air conditioning
Refrigerant R134a, vacuum pumping including filling (charging)
Refrigerant, filling incl vacuum pumping
Relief Cut-in pressure, check
Relief ut-in pressure, adjusting
Repair instructions
Replacement of pivot pin for accelerator pedal and retarder pedal
Replacing damping cylinder
Reporting of accidents and incidents
Reporting of product misuse & near-miss report
Reverse gear R1
Reverse gear R2
Rocker arm shaft, tightening torques
Routine for return of technical goods
Rubber cushion, replacing
SAE J1708 (Information bus)
SAE J1939 CAN-bus (control bus)
Safety concerns everybody!
Safety for work on hydraulic systems
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting the machine
Safety when working with air-conditioning refrigerant
Safety when working with batteries
Seal for rear output shaft, replacing
Section 4, content, structure
Service and maintenance of batteries
Service connection and programming connection
Service Manual IL-1, supplement
Service Manual, supplement
Side window, replacing
Special tools
Spindle, replacing one side
Stall speed, checking
Standard tightening torques
Starter motor, replacing 1
Starter motor, replacing
Starter motor, specification 1
Starter motor, specification 2
Starter motor, tightening torques
Starting with booster batteries 1
Starting with booster batteries
Steering and dumping valve, description
Steering and dumping valve, overview illustration 1
Steering and dumping valve, overview illustration 2
Steering and dumping valve, removed, reconditioning 1
Steering and dumping valve, removed, reconditioning
Steering and dumping valve, specifications
Steering and dumping valve, tightening torques
Steering and hydraulics, basic check
Steering and tipping valve, installation
Steering and tipping valve, removal
Steering angle, checking and adjusting
Steering cylinder bearing, introduction of grease nipples
Steering cylinder, description 1
Steering cylinder, description
Steering cylinder, installation
Steering cylinder, reconditioning on machine
Steering cylinder, removal
Steering cylinder, removed, reconditioning
Steering cylinder, replacing bearings 1
Steering cylinder, replacing bearings 2
Steering cylinder, replacing bearings
Steering cylinder, specifications
Steering gear, check.and adj.
Steering gear, replacing
Steering gear, specifications
Steering joint bearing
Steering joint, replacing bearings
Steering joint, vertical joint, introduction of grease nipples
Steering linkage, checking and adjusting 1
Steering linkage, checking and adjusting
Steering system, description
Steering system, specifications
Steering times, checking and adjusting
Steering valve, neutral position, checking and adjusting
Suspension, description
T-ECU, MID 130, changing non-Programd ECU
T-ECU, MID 130, changing pre-Programd ECU
Thermostat, replacing 1
Thermostat, replacing
Thermostat, specifications
Tightening torque, cylinder head
Tightening torque, fuel system
Tightening torque
Tightening torques, engine mounts
Tightening torques, valve cover
Timing gear casing, leakage
Tipping system, specification
Torque limiter, description
Torque limiting valve, checking and adjusting 1
Torque limiting valve, checking and adjusting
Tractor unit frame
Transfer gearbox, description
Transmission of power
Transmission PowerTronic, new B2 drum
Transmission PowerTronic, new gasket
Transmission PT1560, cut-away
Transmission PT1663, reinforced bolted joint, converter housing – transmission housing
Transmission, adaptive gear shifting
Transmission, clutches and brakes
Transmission, functional check
Transmission, improved retarder
Transmission, inspection form
Transmission, installing from underneath
Transmission, installing
Transmission, mounting on engine out of machine, version 1
Transmission, mounting on engine out of machine, version 2
Transmission, oil pressure
Transmission, removing 1
Transmission, removing downward
Transmission, removing from engine out of machine, version 1
Transmission, removing from engine out of machine, version 2
Transmission, specifications
Transmission, tightening torques
Transporting the machine
Transverse differential lock-axle, checking and adjusting
Troubleshooting strategy 1
Troubleshooting strategy
Troubleshooting tips 1
Troubleshooting tips
Troubleshooting, air conditioning unit (AC)
Troubleshooting, assistant devices
Troubleshooting, general
Turbocharger, description
Turbocharger, inspection
Turbocharger, replacing
Turbocharger, specifications
Tyre equipment and recommended tyre pressures 1
Tyre equipment and recommended tyre pressures 2
Tyres, various types
Unit injector, adjusting pretension
Unit injector, replacing
Unit injectors, description
Unit injectors, specifications 1
Unit injectors, specifications
V
Vacuum pump, connection
Vacuum pump, disconnection
Valve mechanism, description
Valve mechanism, specifications 1
Valve mechanism, specifications 2
Valve spring update, D9, D12 and D16
Valves and unit injectors, adjusting – D9A
Valves, adjusting 1
Valves, adjusting 2
Valves, adjusting
VCADS Pro service tool, general
VCADS Pro tests 1
VCADS Pro tests
VCADS Pro, Calibrating
VCADS Pro, Error codes
VCADS Pro, Programming
VCADS Pro, Test
V-ECU, MID 187, changing non-Programd ECU 1
V-ECU, MID 187, changing non-Programd ECU
V-ECU, MID 187, changing pre-Programd ECU
Warranty inspection 100 hours
Warranty inspection 1000 hours 1
Warranty inspection 1000 hours
Warranty inspection
Waste handling
Water separator
Weights
Wheel alignment
Wheel, removing and fitting one
Wheel, tightening torque
Windows, general
Windscreen wiper front, replacing motor
Windscreen wiper motor, tightening torques
Wiring diagram A01
Wiring diagram A01-1
Wiring diagram A01-2
Wiring diagram A01-3
Wiring diagram A01-4
Wiring diagram A01-5
Wiring diagram A02
Wiring diagram A03-1
Wiring diagram A03-2
Wiring diagram A03-3
Wiring diagram A04
Wiring diagram A04-1
Wiring diagram A04-2
Wiring diagram A04-3
Wiring diagram A04-4
Wiring diagram A04-5
Wiring diagram A04-6
Wiring diagram A04-7
Wiring diagram A04-8
Wiring diagram A05-1
Wiring diagram A05-2
Wiring diagram A05-3
Wiring diagram A05-4
Wiring diagram A06-1
Wiring diagram A06-2
Wiring diagram A07-1
Wiring diagram A07-2
Wiring diagram A07-3
Wiring diagram A07-4
Wiring diagram A08-1
Wiring diagram A08-2
Wiring diagram A09-1
Wiring diagram A09-2
Wiring diagram A10-1
Wiring diagram A10-2
Wiring diagram A10-3
Wiring diagram A11
Wiring diagram A11-1
Wiring diagram A11-2
Wiring diagram A11-3
Wiring diagram A11-4
Wiring diagram A11-5
Wiring diagram A11-6
Wiring diagram A11-7
Wiring diagram A11-8
Wiring diagram A12-1
Wiring diagram A12-2
Wiring diagram A12-3
Wiring diagram A12-4
Wiring diagram A13
Wiring diagram A14-1
Wiring diagram A14-2
Wiring diagram A14-3
Wiring diagram A14-4
Wiring diagram A15-1
Wiring diagram A15-2
Wiring diagram A15-3
Wiring diagram A16-1
Wiring diagram A16-2
Wiring diagram A17-1
Wiring diagram A17-2
Wiring diagram A18-1
Wiring diagram A18-2
Wiring diagram A18-3
Wiring diagram A18-4
Wiring diagram A18-5
Wiring diagram A19-1
Wiring diagram A19-2
Wiring diagram A19-3
Wiring diagram A19-4
Wiring diagram A19-5
Wiring diagram A20-1
Wiring diagram A20-2
Wiring diagram A20-3
Wiring diagram A21-1
Wiring diagram A21-2
Wiring diagram A21-3
Wiring diagram A22-1
Wiring diagram A22-2
Wiring diagram A22-3
Wiring diagram A22-4
Wiring diagram A23-1
Wiring diagram A23-2
Wiring diagram A23-3
Wiring diagram A23-4
Wiring diagram A24-1
Wiring diagram A24-2
Wiring diagram A24-3
Wiring diagram A24-4
Wiring diagram A24-5
Wiring diagram A24-6
Wiring diagram A25-1
Wiring diagram A25-2
Wiring diagram A25-3
Wiring diagram A25-4
Wiring diagram A25-5
Wiring diagram A25-6
Wiring diagram A26-1
Wiring diagram A26-2
Wiring diagram A26-3
Wiring diagram A26-4
Wiring diagram A27-1
Wiring diagram A27-2
Wiring diagram A27-3
Wiring diagram A27-4
Wiring diagram A28-1
Wiring diagram A28-2
Wiring diagram A28-3
Wiring diagram A28-4
Wiring diagrams
Working in environmentally contaminated areas
Working on the electrical system of the machine

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