Volvo A30G Dump Truck Service and Repair Manual PDF

Volvo A30G Dump Truck Service and Repair Manual PDF

Size: 146.05 MB
Language: English
Make: Volvo
Machine: Dump Truck
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Model: Volvo A30G
Page: 1563 Pages

Detail Contents:
1 Volvo A30G
Brakes

• Accumulator removed, checking charging pressure
  Accumulator, replacing
  Brake cooling circulation, function check
  Brake disc, replacing
  Brake system, bleeding
  Brake system, checking function, hydraulic
  Brake system, relieve pressure
  Compressed air system, component location
  Compressor, replacing
  Foot brake valve, replacing
  Hydraulic pump, checking and adjusting max working pressure
  Load and Dump brake, function check
  Load and Dump brake, servo pressure, checking
  Load and dump brake, working pressure, checking and adjusting
  Parking brake, adjusting
  Parking brake, function checking
  Parking brake, manually releasing
  Parking brake, replacing brake disc
  Parking brake, replacing brake pads
  Pressure check connections, description
  Pressure release
  Pump unit brake cooling, replacing
  Pump, installation
  Pump, removal
  Quick coupling compressed air, replacing
  Relief Cut-in pressure, adjusting
  Relief Cut-in pressure, check
  Spring brake cylinder, replacing
  Tech Tool, operations
  Wear indicator, adjusting

Diagrams

• Compressed air diagram
  Compressed air diagram1
  Electrical component list
  Electrical distribution box, description
  Electrical symbols and designations
  Explanation of wiring diagrams
  Explanations to hydraulic diagram
  Hydraulic diagram PT
  Hydraulic diagram PT1
  Hydraulic diagram, complete 2
  Hydraulic diagram, complete 3
  Hydraulic diagram, complete 4
  Hydraulic diagram, complete 5
  Hydraulic diagram, complete
  Hydraulic diagram, complete
  Hydraulic diagram, complete1
  Hydraulic diagram, complete2
  Hydraulic diagram, complete3
  Steering and dumping valve, overview illustration
  Wiring diagram WD201.1
  Wiring diagram WD201
  Wiring diagram WD202
  Wiring diagram WD203
  Wiring diagram WD204
  Wiring diagram WD205
  Wiring diagram WD206
  Wiring diagram WD207
  Wiring diagram WD208
  Wiring diagram WD240
  Wiring diagram WD241
  Wiring diagram WD242
  Wiring diagram WD243
  Wiring diagram WD244
  Wiring diagram WD301
  Wiring diagram WD302
  Wiring diagram WD303
  Wiring diagram WD304
  Wiring diagram WD305.1
  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 WD317
  Wiring diagram WD318
  Wiring diagram WD319
  Wiring diagram WD320
  Wiring diagram WD321
  Wiring diagram WD322
  Wiring diagram WD323
  Wiring diagram WD324
  Wiring diagram WD325
  Wiring diagram WD327
  Wiring diagram WD328
  Wiring diagram WD329
  Wiring diagram WD330
  Wiring diagram WD401
  Wiring diagram WD402
  Wiring diagram WD403
  Wiring diagram WD501
  Wiring diagram WD502
  Wiring diagram WD503
  Wiring diagram WD504
  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 WD905
  Wiring diagrams

Electrical system

• Alternator, replacing incl function check
  Alternator, replacing incl function check1
  Batteries, replacing
  CareTrack antenna, replacing
  Component position 1
  Component position 5
  Component position 6
  Component position 8
  Component position 9
  Component position 10
  Component position 12
  Component position 13
  Component position 15
  Control units, changing
  Engine Gateway, MID 165, replacing non-Programd ECU
  Engine gateway, MID 165, replacing pre-Programd ECU
  Flasher lamp front glass or bulb, replacing
  Flasher lamp sidelight glass or bulb, replacing
  Headlight, complete, changing (high beam 1 pc.) incl. setting
  Headlight, complete, changing (low beam 1 pc.) incl. setting adjustment
  Headlights, adjusting
  Lamp bulb, replacing
  Starter motor, replacing
  Tail lamp, replacing
  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

Engine

• ACM (After treatment control module), replacing, non-Programd
  ACM (After treatment control module), replacing, pre-Programd
  AdBlue® DEF pump unit, replacing
  AdBlue® DEF quality, checking
  AdBlue® DEF, draining
  AdBlue®DEF dosing injector, replacing
  AdBlue®DEF tank, tank armature, replacing
  Air in fuel system, checking
  Camshaft setting, checking
  Camshaft, replacing
  Carbon dioxide in coolant system, checking
  Carbon dioxide in fuel system, check
  Compression test
  Cooling fan motor, intercooler, checking adjusting high rpm
  Cooling fan motor, intercooler, checking adjusting low rpm
  Cooling fan motor, radiator, checking adjusting low rpm
  Cooling fan motor, radiator, checking high rpm
  Crankcase ventilation separator, replacing
  Crankshaft, axial clearance, checking
  Crankshaft, replacing front oil seal
  Crankshaft, replacing rear oil seal
  Engine and transmission, mounting
  Engine and transmission, removing
  Engine mounting rear, changing
  Engine rotation speed sensor (camshaft), replacing
  Engine rotation speed sensor, replacing
  Feed pump, checking feed pressure
  Fuel pump, inspection
  Fuel system, bleeding
  Fuel system, component location
  Injector sleeves, replacing
  Lubrication oil pressure, checking with pressure gauge
  Lubrication pressure rocker arm shaft, check
  Lubrication system, component locations
  NOx sensor, replacing 1
  NOx sensor, replacing
  Overflow valve, replacing
  Radiator, adjusting
  Rubber cushion, replacing
  SCR system, dosing test
  Stall speed, checking
  Turbocharger, inspection
  Turbocharger, replacing
  Unit injector, replacing
  Unit injectors, adjusting pretension
  Valves, adjusting 1

Hydraulic System

• Accumulator, discarding
  Automatic lubrication pump unit, reconditioning
  Bleeding air
  Change of lubrication interval
  Cylinder, rear flap, gas pressure, checking and adjusting
  Dosage valve, checking internal leakage
  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
  Filling lubricant
  Fire suppression system, actions after activation
  Fire suppression system, actions after manual activation
  Fire suppression system, component location
  Hoist cylinder bearing, changing
  Hoist cylinder removed, reconditioning
  Hoist cylinder, installation
  Hoist cylinder, removal
  Hydraulic couplings
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump, checking and adjusting max working pressure
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic system, bleeding
  Hydraulic system, relieve pressure
  Lubrication points, central lubrication
  Pressure check connections, description
  Pump regulator, checking
  Pump, installation
  Pump, removal
  Rubber connection, suction line, replacing
  Shift valve, checking
  Steering and dumping valve, removed, reconditioning
  Steering and tipping valve, installation
  Steering and tipping valve, removal
  System test
  Tech Tool, operations
  V2-ECU, MID 249, changing non-Programd ECU
  V2-ECU, MID 249, changing pre-Programd ECU
  Vacuum pump, connection
  Vacuum pump, disconnection
  Working pumps, checking function

Machinery House and AC

• Auxiliary heater, replacing
  Cab heating cab ventilation timer, pump, replacing
  Cab, installing
  Cab, removing
  Compressor operator’s seat, replacing
  Compressor, replacing incl draining and filling
  Condenser, replacing incl draining and filling
  Cooling unit, performance test
  Door lock, replacing
  Door window, replacing
  Door, gas spring, replacing
  Door, replacing
  ECC, MID 146, changing non-Programd ECU
  ECC, MID 146, changing pre-Programd ECU
  Electric hood pump, changing
  Engine hood, installing
  Engine hood, removing
  Evaporator, cleaning
  Evaporator, replacing incl draining and filling
  Fan motor, replacing
  Heat control valve, replacing
  Heat control, replacing
  Heater core, replacing
  Hood pump, oil, changing
  Operator’s seat, air bellows, replacing
  Operator’s seat, air bellows, replacing1
  Operator’s seat, installing
  Operator’s seat, installing1
  Operator’s seat, removing
  Operator’s seat, removing1
  Operator’s seat, shock absorber, replacing
  Rear window, replacing
  Receiver, replacing incl draining and filling
  Refrigerant, draining
  Refrigerant, filling incl vacuum pumping
  Side window, rear, replacing
  Side window, replacing
  Troubleshooting, air conditioning unit (AC)
  Windscreen, replacing

Maintenance

• 88830227 88830228 User instruction
  AdBlue® DEF pump unit filter, replacing
  Air drier cartridge, replacing
  Alternative exit, checking
  Automatic central lubrication filter, replacing
  Axle breather filters, replacing
  Basic service
  Brake cooling oil level, checking
  Brake cooling oil tank breather filter, replacing
  Brake cooling oil, changing
  Brake cooling tank return oil filter and magnetic rods, cleaning and replacing
  Brake system pressure oil filter, replacing
  Brake system, basic check
  Cab asbestos filter, replacing
  Cab main filter, replacing
  Cab prefilter, replacing
  Condition test and maintenance program
  Draining-Filling pump, user instructions
  Drive axles and hubs oil, changing
  Drive axles leakage, checking
  Drive belts, checking
  Dropbox and front axle, breather filter, replacing
  Dropbox leakage, checking
  Dropbox oil, changing
  Dump body alternative, lowering
  E-ECU, MID 128, changing non-Programd ECU
  E-ECU, MID 128, changing pre-Programd ECU
  Electrical system, basic check
  Engine and dropbox mounts, checking
  Engine oil and filter, changing
  Engine, basic check
  Exhaust heated load body, checking, cleaning and greasing
  Extra fuel prefilter, replacing
  Fire suppression system, checking
  Frame extension bolted joints torque, checking
  Frame joint bearings clearance, checking
  Fuel filters, replacing
  Fuel system extra fuel pre- filter, draining
  Fuel tank breather filter, replacing
  Fuel tank sediment, draining
  Hydraulic oil level, checking
  Hydraulic oil tank breather filter, replacing
  Hydraulic oil, changing
  Hydraulic tank return oil filter and magnetic rod, cleaning and replacing
  Hydraulic tank sediment, draining
  Load body rubber cushions clearance, checking
  Lubrication, every 250 hours
  Lubrication, every 500 hours
  Lubrication, every 1000 hours
  Lubrication, every 2000 hours
  Maintenance service, every 10 hours
  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 6000 hours
  Maintenance service, first 100 hours
  Maintenance service, first 1000 hours
  Parking brake function, checking
  Parking brake pads, checking
  Parking brake, basic check
  Parking brake, manually releasing
  Power take-off suction strainer, cleaning
  Power transmission, basic check
  Propeller shaft movement, checking
  Propeller shafts, removing
  Restoring from serviceposition
  Restoring of the machine
  Secondary steering, checking
  Service brake disc wear, checking
  Service points
  Service position 1
  Starting with booster batteries
  Steering and hydraulics, basic check
  Steering cylinder bearings clearance, checking
  Steering joint bearing, checking
  Suspension cylinder (GHS) oil, changing
  Suspension cylinder (GHS) rubber bearings, checking
  Suspension cylinder (GHS), checking
  Tech Tool, operations
  Transmission breather filter, replacing
  Transmission oil filter, replacing
  Tyre wear and air pressure, checking
  Valves, adjusting

Power Transmission

• Centre gear , removing and fitting
  Centre gear, removing and fitting
  Differential lock longitudinal, adjustment of sender unit
  Dog clutch 6-wheel drive, adjusting
  Dropbox rubber bushing, replacing
  Dropbox, installing
  Dropbox, removing
  Dropbox, replacing seal for front otput shaft
  Dropbox, replacing seal for rear output shaft
  Hub reduction gear, disassembly and assembly
  Hub reduction, installing
  Hub reduction, removing
  Induction sensor for turbine speed, changing
  Input shaft seal, replacing
  Input shaft, seal, replacing 1
  Input shaft, seal, replacing
  Output shaft, bearing and seal, replacing
  Pressure testing
  PWM-valve control system, changing
  Rotation speed sensor, adjusting
  Seal for rear output shaft, replacing
  Tech Tool, operations
  Transmission oil pressure, checking
  Transmission, fitting on a non mounted engine
  Transmission, installing
  Transmission, remove from a non mounted engine
  Transmission, removing
  Transverse differential lock axle, checking and adjusting

Service Bulletins

• Action to be taken in case of abnormal lubricating oil consumption
  Alternative lubricants for axles with wet brakes
  Automatic transmission lubricants
  Battery and alternator test procedure
  Fuel sampling, method
  Information on Bio-diesel fuel (RME-fuel)
  New Articulated Haulers F- and G-series
  New tip lever
  Oil sampling, method
  Quality of illustrations in technical reports
  Recommendations for Oil Sampling Intervals
  Reporting of product misuse & near-miss report
  Reports
  TechTool 2 communication
  Transmission, functional check
  Transmission, inspection form
  Tyres, various types
  Volvo Product incident accident report & Interview Form
  Water in engine compartment

Steering

• Auxiliary steering, adjusting working- and stand-by pressure
  Auxiliary steering, hydraulic pump, installation
  Auxiliary steering, hydraulic pump, removing
  Damping cylinder, changing seal
  Damping cylinder, checking spring force
  Lever bracket, steering bearing, replacing
  Steering angle, checking and adjusting
  Steering cylinder removed, reconditioning excl replacing bearings
  Steering cylinder, installing
  Steering cylinder, removing
  Steering cylinder, replacing bearings
  Steering cylinder, replacing bearings1
  Steering gear, check.and adj.
  Steering gear, replacing
  Steering linkage, checking and adjusting
  Steering times, checking and adjusting
  Steering valve, neutral position, checking and adjusting

Suspension

• A-frame bushing, front on load unit, changing
  A-frame bushing, rear on load unit, changing
  A-frame bushing, tractor unit, replacing
  Bogie beam, changing rubber bushing on removed beam
  Bogie beam, changing rubber spring, one side (front)
  Cross stay, installing
  Cross stay, removing
  Cross stay, rubber bushing, replacing
  Frame joint bearing, replacing (machine separated)
  Frame joint bearings, clearance, check
  Frame joint, separating machine
  Hitch, installing
  Hitch, removing
  Hydraulic cylinder bushing, suspension system, replacing
  Hydraulic cylinder, suspension system, overhaul
  Steering joint bearing, replacing (Hitch removed)
  Steering joint, replacing bearings
  Suspension cylinder (GHS), checking and adjusting
  Suspension cylinder (GHS), discarding
  Suspension cylinder (GHS), oil changing
  Suspension cylinder, installation
  Suspension cylinder, removal
  Wheel alignment
  Wheel, installing
  Wheel, removing

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