Volvo A25F Dump Truck Service and Repair Manual PDF

Volvo A25F Dump Truck Service and Repair Manual PDF

Size: 140.08 MB
Language: English
Make: Volvo
Machine: Dump Truck
Document: Service Repair Manual, Electrical Diagram, Hydraulic Diagram
Model: Volvo A25F
Page: 1781 Pages

Detail Contents:
1 Volvo A25F
Descriptions

• A–frame
  Air cleaner, description
  Alternator, description
  Anti-theft device, description
  ATC, description
  Automatic brake description
  Automatic central lubrication
  Auxiliary brake (engine braking), description
  Auxiliary steering backwards, description
  Axle suspension, description
  Back-up alarm, description
  Basic check, transmission
  Basic checks
  Battery, charging
  Battery, description
  Bogie extension, description
  Braking system, description
  Cab description
  Cab, lifting points
  CareTrack Telematics system
  CE-marking, EMC-directive
  Charge air cooling system, description
  Climate control system, description
  Clutches, brakes and planet stages, description
  Collection of basic data
  Component locations
  Component position
  Compressed air system, pressure build-up
  Connectors, position
  Control system, description
  Control system
  Control unit, description
  Control units, voltage supply
  Coolant with anti-freeze and corrosion protection, recommendation
  Cooling fan speed control, description
  Cooling need, overview illustration
  Cooling system, description
  Cooling system, principle illustrations
  Crank mechanism, description
  Crankcase ventilation, description
  Cylinder block, description
  Cylinder liners and pistons, description
  Damping cylinder, description
  Data bus system
  Delayed stop, description
  Diagnostic tools, description
  Display, description
  Door open, description
  Dosage valves, description
  Drive axles, description
  Drivetrain, description
  Dump function, description
  EGR system, tightening torques
  Electrical system, special instructions for servicing, actions when working on machine
  Electrical system, special instructions for servicing, electrical components, batteries
  Electrical system, special instructions for servicing, electronic components
  Electrical system, special instructions for servicing, general
  Electronic accelerator pedal, description
  Engine- and cab heater, description
  Engine and transmission overspeed protection, description
  Engine hood, description
  Engine timing gear, description
  Engine, description 1
  Engine, description
  Engine, identification
  Engine, sensor locations
  Exhaust Aftertreatment System, component location
  Exhaust Aftertreatment System, description
  Exhaust gas recirculation (EGR), component location
  Exhaust Gas Recirculation (EGR), description
  Exhaust pressure governor
  External activation of central warning, description
  Foot brake valve, description
  FOPS and ROPS
  Frame joint, description
  Frame, description
  Fuel feed pump, description
  Fuel filter housing, description
  Fuel flow, description
  Fuel level, description
  Fuel system, description
  Gear selector
  Gear shifting strategy
  Gearshifting, description
  General vehicle electronics
  Heat exchanger, description
  Hoist cylinder, description
  Hydraulic brake system, pressure build-up
  Hydraulic components, cleanliness when handling
  Hydraulic oil tank, description
  Hydraulic oil, storing and handling
  Hydraulic pump flow regulation, description
  Hydraulic pump, description
  Hydraulic system, description
  Hydraulic system, repair of hydraulic components in workshop
  Hydraulic system, work instructions
  Inclination, description
  Information display unit, summary
  Information display, cycle info
  Information display, electrical system
  Information display, engine
  Information display, general
  Information display, hydraulics
  information display, machine information
  Information display, service
  Information display, transmission
  Information display, vehicle messages
  Inlet and exhaust system, component location 1
  Inlet and exhaust system, component location
  Inlet and exhaust system, description 1
  Inlet and exhaust system, description
  Load and dump brake, description
  Load unit frame
  Lock-up clutch
  Lubrication and oil system
  Lubrication system, description
  Main oil filter
  MS.Internal.Documents
  Oil level
  Oil pump, description
  Oil temperature
  Oil trap, description
  Parameter settings
  Parking brake, function description
  Personal competence and accreditation
  Preheating description
  Pressure build up, steering
  Pressure check connections, description
  Pressure monitor, description
  Propeller shaft, description
  PT Transmission
  PTO (Power Take Off), description
  Pump unit, description
  Rear view monitor, service menu
  Red extra central warning, description
  Regeneration process, description
  Retarder pedal, description
  Retarder, description
  SAE J1708 (Information bus)
  Safety when working with air-conditioning refrigerant
  Seat belt supervision, description
  Secondary steering, description
  Sensors and monitors, description
  Sensors, description
  Service connection and programming connection
  Service mode, description
  Service
  Shift valve, description
  Software parameters, description
  Start electronics, description
  Starter motor, description
  Steering and dumping valve, description
  Steering cylinder, description
  Steering system, description twin steer
  Steering system, description
  Stop electronics, description
  Supervision data bus communication, description
  Suspension cylinder (GHS), description
  Suspension, description
  System voltage, description
  Thermostat, secondary system, description
  Torque converter
  Tractor unit frame
  Transfer gearbox, description
  Transmission, description
  Troubleshooting, assistant devices
  Turbocharger, description
  Unit injectors, description
  Vehicle speed, description
  Wheel brake, description
  Working lights, description

Diagrams

• Compressed air diagram
  Electrical component list
  Electrical distribution box, description
  Electrical symbols and designations
  Explanation of wiring diagrams
  Explanations to hydraulic diagram
  Hydraulic diagram pic 1
  Hydraulic diagram PT
  Hydraulic diagram, brake system
  Hydraulic diagram, complete pic 1
  Hydraulic diagram, complete
  Hydraulic diagram, hood opening
  Hydraulic diagram
  Steering and dumping valve, overview illustration
  Wiring diagram WD201
  Wiring diagram WD202
  Wiring diagram WD203
  Wiring diagram WD204
  Wiring diagram WD205
  Wiring diagram WD206
  Wiring diagram WD207
  Wiring diagram WD220
  Wiring diagram WD240
  Wiring diagram WD241
  Wiring diagram WD242
  Wiring diagram WD301
  Wiring diagram WD302
  Wiring diagram WD303
  Wiring diagram WD304
  Wiring diagram WD305
  Wiring diagram WD306
  Wiring diagram WD307
  Wiring diagram WD308
  Wiring diagram WD309
  Wiring diagram WD310
  Wiring diagram WD311
  Wiring diagram WD312
  Wiring diagram WD313
  Wiring diagram WD314
  Wiring diagram WD315
  Wiring diagram WD316
  Wiring diagram WD318
  Wiring diagram WD320
  Wiring diagram WD321
  Wiring diagram WD322
  Wiring diagram WD323
  Wiring diagram WD324
  Wiring diagram WD325
  Wiring diagram WD326
  Wiring diagram WD327
  Wiring diagram WD328
  Wiring diagram WD401
  Wiring diagram WD403
  Wiring diagram WD501
  Wiring diagram WD502
  Wiring diagram WD503
  Wiring diagram WD504
  Wiring diagram WD702
  Wiring diagram WD801
  Wiring diagram WD802
  Wiring diagram WD803
  Wiring diagram WD804
  Wiring diagram WD805
  Wiring diagram WD901
  Wiring diagram WD902
  Wiring diagram WD903
  Wiring diagram WD907
  Wiring diagram WD908
  Wiring diagram WD909
  Wiring diagram WD910
  Wiring diagram WD911
  Wiring diagram WD912
  Wiring diagrams

Repair

• Accumulator removed, checking charging pressure
  Accumulator, discarding
  Accumulator, replacing
  A-frame bushing, front on load unit, changing
  A-frame bushing, rear on load unit, changing
  A-frame bushing, tractor unit, replacing
  Air pump, oil level, checking
  Air pump, oil, changing
  Alternator, replacing incl function check
  Automatic lubrication pump unit, reconditioning
  Auxiliary heater, replacing
  Auxiliary steering, adjusting working- and stand-by pressure
  Auxiliary steering, hydraulic pump, installation
  Auxiliary steering, hydraulic pump, removing
  Axles and dropbox, leaks, checking
  Batteries, replacing
  Battery, charging state, electrolyte level, cables and connections, especially connections at starter motor, check
  Belts and belt tension, check, replace when needed.
  Bleeding air
  Bogie beam, changing rubber bushing on removed beam
  Bogie beam, changing rubber spring, one side (front)
  Bogie beam, changing
  Brake caliper, replacing one
  Brake calliper removed, reconditioning
  Brake calliper, replacing one
  Brake disc, replacing one
  Brake pads, replacing (one wheel, 2d boggie axle)
  Brake pads, replacing (one wheel, first boggie axle)
  Brake pads, replacing (one wheel, front axle)
  Brake system, basic check
  Brake system, bleeding1
  Brake system, bleeding2
  Brake system, checking function, hydraulic
  Brake system, relieve pressure
  Cab heating cab ventilation timer, pump, replacing
  Cab, installing
  Cab, main filter, replacing
  Cab, prefilter, replace
  Cab, removing
  CareTrack antenna, replacing
  Centre gear , removing and fitting
  Centre gear, removing and fitting
  Change of lubrication interval
  Checking and adjusting the longitudinal differential lock
  Checking of main, torque converter and lubricating oil pressure
  Check-measuring electric components
  Compressor, replacing incl draining and filling
  Compressor, replacing
  Condenser, replacing incl draining and filling
  Condition test and maintenance program
  Control system, reconditioning
  Control units, changing
  Coolant’s freezing point, check
  Cooling unit, performance test
  Cross stay, installing
  Cross stay, installing2
  Cross stay, removing
  Cross stay, removing1
  Cross stay, rubber bushing, replacing
  Cross stay, rubber bushing, replacing1
  Cylinder, rear flap, gas pressure, checking and adjusting
  Damping cylinder, changing seal
  Damping cylinder, checking spring force
  Differential lock longitudinal, adjustment of sender unit
  Dog clutch 6×6, checking and adjusting
  Door lock, replacing
  Door window, replacing
  Door, gas spring, replacing
  Door, replacing
  Dosage valve, checking internal leakage
  Dropbox, installing
  Dropbox, removing
  Dropbox, replacing seal for front otput shaft
  Dropbox, replacing seal for rear output shaft
  Dump body alternative, lowering
  Dump body angle sensor, calibration
  Dump body joint, changing tipping bearing
  Dump body, adjusting against frame
  Dump function, checking pressure
  Dump lever, changing
  E-1763
  E-2000
  E-2511
  E-2519
  E-2520
  E-2521
  E-2524
  E-2525
  E-2526
  E-2527
  E-2528
  ECC, MID 146, changing non-Programd ECU
  ECC, MID 146, changing pre-Programd ECU
  Electric hood pump, changing
  Electrical system, basic check
  Engine hood, installing
  Engine hood, removing
  Engine mounts and dropbox mounts, checking
  Engine, basic check
  Evaporator, cleaning
  Evaporator, replacing incl draining and filling
  Fan motor, replacing
  Filling lubricant
  Foot brake valve, replacing
  Frame extension, bolted joints, torque, check
  Frame joint bearing, replacing (machine separated)
  Frame joint bearings, clearance, check
  Frame joint, separating machine
  Front guard plate, removing
  Headlights, adjusting
  Heat control valve, replacing
  Heat control, replacing
  Heater core, replacing
  Hitch, installing
  Hitch, removing
  HMIM, MID 140, changing non-Programd ECU
  HMIM, MID 140, changing pre-Programd ECU
  Hoist cylinder bearing, changing1
  Hoist cylinder bearing, changing2
  Hoist cylinder removed, reconditioning1
  Hoist cylinder removed, reconditioning2
  Hoist cylinder, installation
  Hoist cylinder, removal
  Hood pump, oil, changing
  Hub reduction, installing
  Hub reduction, removing
  Hydraulic couplings
  Hydraulic cylinder bushing, suspension system, replacing
  Hydraulic cylinder, suspension system, overhaul
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump, checking and adjusting max working pressure
  Hydraulic pump, checking and adjusting max working pressure1
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic pump, installation
  Hydraulic pump, removal
  Hydraulic system, bleeding
  Hydraulic system, relieve pressure
  Induction sensor for output shaft, changing
  Induction sensor for turbine speed, changing
  Instructions for drilling in ROPS structure
  Intermediate shaft and or bearing, replacing (in frame joint)
  Lever bracket, steering bearing, replacing
  Load and Dump brake, function check
  Load and dump brake, servo accumulator, checking2
  Load and Dump brake, servo pressure, checking1
  Load and dump brake, working pressure, checking and adjusting
  Lubrication points, central lubrication
  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
  Maintenance service, every 4000 hours
  Maintenance service, every 4500 hours
  Maintenance service, every 6000 hours
  Maintenance service, every 8000 hours
  Maintenance service, every 12000 hours
  Maintenance service, first 100 hours
  Maintenance service, first 1000 hours
  MATRIS and Tech Tool, reading
  Operator’s seat, air bellows, replacing
  Operator’s seat, installing
  Operator’s seat, removing
  Operator’s seat, shock absorber, replacing
  Output shaft 6-wheel drive, sealing and bearing, replacing
  Parking brake , replacing brake caliper
  Parking brake, adjusting
  Parking brake, basic check
  Parking brake, function checking
  Parking brake, manually releasing
  Parking brake, replacing brake disc
  Parking brake, replacing brake pads
  Parking brake, replacing
  Power take-off, between engine and gearbox, reconditioning
  Power transmission, basic check
  Pressure check connections, description
  Pressure check connections, description1
  Pressure release
  Propeller shaft, play, checking
  Protecting plate, installation
  Protecting plate, removal
  Pump regulator, checking
  Pump, installation
  Pump, removal
  PWM-valve control system, changing
  Quick coupling compressed air, replacing
  Rear guard plates, removing
  Rear window, replacing
  Receiver, replacing incl draining and filling
  Relief Cut-in pressure, adjusting
  Relief Cut-in pressure, check
  Retarder valve, reconditioning
  Retarder valve, replacing
  Rotation speed sensor, adjusting
  Rotation speed sensor, replacing
  Seal for rear output shaft, replacing
  Secondary steering, checking
  Service points
  Shift valve, checking
  Side window, rear, replacing
  Side window, replacing
  Spindle, replacing one side
  Spindle, replacing one side1
  Spring brake cylinder, replacing
  Starter motor, replacing
  Steering and dumping valve, removed, reconditioning
  Steering and hydraulics, basic check
  Steering and tipping valve, installation
  Steering and tipping valve, removal
  Steering angle, checking and adjusting
  Steering cylinder removed, reconditioning excl replacing bearings
  Steering cylinder, installing
  Steering cylinder, removing
  Steering cylinder, replacing bearings1
  Steering cylinder, replacing bearings2
  Steering gear, check.and adj.
  Steering gear, replacing
  Steering joint, replacing bearings
  Steering linkage, checking and adjusting
  Steering linkage, checking and adjusting1
  Steering system, bleeding
  Steering times, checking and adjusting
  Steering valve, neutral position, checking and adjusting
  Suspension cylinder (GHS), discarding
  Suspension cylinder (GHS), function check
  Suspension cylinder (GHS), oil changing
  Suspension cylinder, installation
  Suspension cylinder, removal
  System test
  Tech Tool, operations
  Tech Tool, operations1
  Test-run and check
  Transmission, fitting on a non mounted engine
  Transmission, installing
  Transmission, remove from a non mounted engine
  Transmission, removing
  Tyres, wear and air pressure, checking
  V2-ECU, MID 249, changing non-Programd ECU
  V2-ECU, MID 249, changing pre-Programd ECU
  Vacuum pump, connection
  Vacuum pump, disconnection
  VCADS Pro, Operations
  VCADS Pro, Operations1
  V-ECU, MID 187, changing non-Programd ECU
  V-ECU, MID 187, changing pre-Programd ECU
  W-ECU, MID142, changing non-Programd ECU
  W-ECU, MID142, changing pre-Programd ECU
  Wheel alignment
  Wheel, installing
  Wheel, removing and fitting one
  Wheel, removing
  Windscreen wiper front, replacing motor1
  Windscreen wiper front, replacing motor2
  Windscreen, replacing
  Working pumps, checking function

Service Bulletins

• Action to be taken in case of abnormal lubricating oil consumption
  Alternative lubricants for axles with wet brakes
  Alternator Improvment
  Automatic transmission lubricants
  Battery and alternator test procedure
  Central lubrication
  Crank shaft pulley adapter
  DEF AdBlue AUS32 sampling, method
  EATS burner, Ignition cables
  EATS functional check
  Front LED parking lights
  Fuel sampling, method
  Heater element
  Hub Seal Leakage AH56 AH64
  Information on Bio-diesel fuel (RME-fuel)
  Long pressure build-up time in Load & Dump brake
  Loose screws on AH Hubs
  Main cab cable harness, chafing
  New air nipple for the diff lock on load unit
  New Articulated Haulers F- and G-series
  New Articulated Haulers, A25F and A30F
  New ASU part number and new EATS fuel pump
  New B5 piston in PT 22416 Transmission
  New body angle sensor
  New cab heater element
  New Caretrack WECU2
  New EATS burner
  New EATS fuel pump
  New E-ECU introduced
  New EECU, ACM and ECC software V2012.1.0
  New expansion tank
  New fuel filter housing
  New GHS Cylinder
  New hitch
  New main cab cable harness
  New method for fuel system bleeding
  New method for installing injectors
  New needle bearings in planet stage 1
  New pressure sensors
  New rear camera system
  New rear LED flasher
  New software for VECU V2013.6.1
  New software update 2011.3.0 for CareTrack
  New software V2011.3.2
  New software V2011.6.0
  New software V2012.3.0
  New software V2012.3.1
  New software V2012.5.0
  New software V2012.5.1
  New software V2013.2.0
  New software V2013.2.1
  New TechTool VCADS Pro interface
  New thrust washers inside planetary step on PT 22416, 22418 and 22419.
  New tip lever
  New torque converter
  New transmission oil pan gasket
  New Venturi tube
  New wheel brake disc
  Noise from hoist cylinder when tipping
  Oil analyses
  Oil sampling, method
  Parking brake switch
  Power cable clamping
  Preheat cable clamping
  Quality of illustrations in technical reports
  Radio band setting
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  Screws, rubber spring bogie
  Semi-automatic regeneration
  Service kit Overhung Tailgate
  Transmission, functional check
  Transmission, inspection form
  Tyres, various types
  Unstable Self steering
  Volvo Product incident accident report & Interview Form

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