Volvo BM 860 Dump Truck Service and Repair Manual PDF

Volvo BM 860 Dump Truck Service and Repair Manual PDF

Size: 78.84 MB
Language: English
Make: Volvo
Machine: Dump Truck
Document: Service Repair Manual
Model: Volvo BM 860
Page: 5022 Pages

Detail Contents:
BM 860 VOLVO

• 4 Service-Manual-Engine 861
  Action for reducing risk of fire
  Action to be taken in case of abnormal lubricating oil consumption
  Adjusting lever 51-1100
  Air cleaner oil bath 24-130
  Air compressor 51-500
  Air drier, drier cartridge, replace
  Air filter 24-100
  Air filter 83-200
  Air-compressor with fitting parts 51-450
  Altered seal in parking brake cylinder
  Alternative lubricants for axles with wet brakes
  Alternator 99002 31-325
  Alternator tillv 31-210
  Alternator tillv 31-200
  Alternator with assembling details 31-150
  Alternator, replacing incl function check
  Anti-freeze reservoir
  Automatic transmission lubricants 1
  Automatic transmission lubricants
  Auxiliary steering, adjusting working- and stand-by pressure
  Auxiliary steering, hydraulic pump, installation
  Auxiliary steering, hydraulic pump, removing
  Axle mounts, bolted joints, tourque, check
  Baffle housing 24-350
  Batteries, replacing
  Battery with assembling details 31-100
  Battery, charging state, electrolyte level, cables and connections, especially connections at starter motor, check
  Belt transmission 22-225
  Bogie suspension 72-50
  Bogie suspension trailing wheel axle 72-100
  Bogie-wheel axle with hub 72-150
  Brake caliper, replacing one 1
  Brake caliper, replacing one
  Brake calliper removed, reconditioning
  Brake calliper, replacing one
  Brake circuit 1, trailer 6×6 51-320
  Brake cylinder 51-810
  Brake disc, replacing one
  Brake fluid level, check
  Brake fluid system, trailer 6×6 51-225
  Brake fluid, change
  Brake pads, replacing (one wheel, 2 d boggie axle)
  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, tractor pipe lines for handbrake Tillv Nr 59472- , 6×6
  Brake system,tractor pipe lines for Footbrake
  Brake system,tractor pipe lines for Handbrake.tillv Nr -59471
  Brake system,tractor pipe lines Inlet And Feeding System
  Brake system,tractor units Tillv Nr – 59471
  Brake unit 51-750
  Cab fan 98972 (6347) 99821
  Cab ventilation 83-150
  Cab, main filter, replacing
  Cab, prefilter, replace
  Camshaft 21-200
  Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope
  Camshaft setting, checking
  Camshaft, replacing
  Carbon monoxide in fuel system, check
  CareTrack new software update including new Conversion kit part numbers for E series haulers and F series loaders
  Centre gear , removing and fitting
  Centre gear, removing and fitting 1
  Centre gear, removing and fitting
  Centrifugal governor 23-300
  Centrifugal governor 23-325
  Changing or repairing hydraulic pumps
  Charge air cooling system 22-75
  Charge air pressure, diesel engines
  Checking and adjusting the longitudinal differential lock
  Checking and adjusting
  Chrome plated brake piston for brake caliper
  Claim routines
  Cleaning of the machine
  Clutches,gears and shafts 41-200
  Cold-starting device 23-350
  Collision protector 98993, 98994
  Compressed air brake, function check
  Compressed air system, drain
  Compression test
  Compressor, replacing
  Condenser, clean (with compressed air) (optional equipment)
  Control cylinder 42-250
  Control duming pipe work 99019, 90365
  Control valve 61-250
  Controls for differential lock 42-150
  Controls for high and low ranges 41-700
  Controls for reduction gear 43-250
  Controls for tipping cylinder 91-200
  Coolant pump removed, reconditioning
  Coolant pump, replacing
  Coolant, changing 1
  Coolant, changing
  Coolant’s freezing point, check
  Cooling fan motor, intercooler, checking adjusting high rpm
  Cooling fan motor, intercooler, checking adjusting low rpm
  Cooling fan, return oil filter, replacing
  Cooling system 22-50
  Cooling system, flushing
  Cooling system, safety valve radiador cap
  Cracks in cylinder head
  Crankshaft and related parts 21-150
  Crankshaft, replacing front oil seal
  Crankshaft, replacing rear oil seal
  Crimping Tool Set, part no. 9993880
  Cylinder balancing, PC test
  Cylinder block 21-100
  Cylinder compression, PC test
  Cylinder head 21-300
  Damping cylinder, changing seal
  Damping cylinder, checking spring force
  Data links, fault tracing with Oscilloscope
  Diesel fuels – quality and function
  Different engine types
  Differential lock 6×6 44-160
  Differential lock longitudinal, adjustment of sender unit 1
  Differential lock longitudinal, adjustment of sender unit
  Differential lock tillv nr -59094
  Differential lock tillv nr 59095-
  Dimensions on the drawing are given in mm.
  Disc brake 6×6 51-900
  Disc brake 51-900
  Dog clutch 6×6, checking and adjusting
  Door tillv nr -59471
  Double joint 43-100
  Draft hook 71-400
  Drawings of E-tools
  Drive axle gear tillv nr -59094
  Drive axle shafts and drive axle tubes 42-100
  Drive axle tillv nr -59094
  Drive axles and hubs, oil, replace
  Drive axles, transmission and dropbox, breather filter, replace
  Drive wheel brake 51-950
  Drive wheel brake bogie
  Drivers cab
  Drivers seat air norseman 98979 99820
  Dropbox, installing
  Dropbox, oil, replace
  Dropbox, removing 1
  Dropbox, removing 2
  Dropbox, removing
  Dump body alternative, lowering
  E1750 Differential lock adjusting tool
  E2502, Installation tool for turbine speed sensor
  E-2519 Measuring nipple
  E-ECU, MID 128, changing pre-Programd ECU 1
  E-ECU, MID 128, changing pre-Programd ECU
  Electric components 31-700
  Electric components 99564 31-725
  Electric components 99824 31-740
  Electrical preheater 31-275
  Electrical system 31-50
  Electrical system, basic check
  Electrical system,trailer6x6 31-75
  Emergency steering 90313 31-850
  Emergency steering 90313 61-75
  Engine and transmission, mounting
  Engine and transmission, removing
  Engine heater 22-300
  Engine mounting 71-100
  Engine mounting rear, changing
  Engine mounts dropbox mounts propeller shafts, bolted joints and flange mounts, check torques
  Engine reconditioning
  Engine rotation speed sensor (camshaft), replacing
  Engine rotation speed sensor, replacing
  Engine with fitting parts 21-50
  Engine, air cleaner, cover, clean
  Engine, air cleaner, main filter, replace. EON (option) only replace when indicated.
  Engine, air cleaner, secondary filter, replace. EON (option) only when indicated
  Engine, basic check
  Engine, oil and filter, change.
  Exhaust brake 24-300
  Exhaust cleaning 99564 Tillv Nr 58589- 24-195
  Exhaust cooling 99004, 99564 24-180
  Exhaust system 24-150
  Exhaust system for underground version 24-155
  Exhaustheated trailerbody98995 (6417) 99522 24-175
  Exhaust-heating 6 x 6 90224 24-185
  Extra flap 98492 71-350
  Extra fuel filter 98980 (6355) Earlier Model 23-550
  Extra fuel filter 98980 Later Model 23-600
  Fan pump, installation 1
  Fan pump, installation
  Fan pump, removing
  Feed pressure, PC test
  Feed pump 23-400
  Feed pump, checking feed pressure
  Final drive 6×6
  Final drive 6×6 44-140
  Final drive ev 80 6×6
  Final gear with housing 42-50
  Foot brake valve (pneum), replacing
  Footbrake valve 51-650
  Footbrake valve with mountings 51-400
  Forward and reverse clutches 41-250
  Frame extension, removing
  Frame joint bearings, clearance, check
  Frame oscillating brake, brake pads, replacing
  Frame,tractor 71-50
  Front bogie axle suspension 6×6 72-200
  Fuel filter 23-500
  Fuel filters, primary and secondary filter, replace
  Fuel injection pump with fitting parts 23-200
  Fuel pipes, injectors 23-100
  Fuel pump, inspection
  Fuel system 23-50
  Fuel system, bleeding
  Fuel tank tillv 23-150
  Fuel tank tillv 23-175
  Fuel tank, hydraulic oil tank, breather filter replace
  Fuel tank, sediment, drain. Shorter interval as needed.
  Grease with molybdenum disulphide additive (MoS2)
  Guard plates tractor
  Guards,mudguards and floor plates 82-200
  Headlamp 31-500
  Headlight 98987 31-550
  Headlight guard 98978 31-575
  Headlight washer 31-300
  Headlight, left asy 98977 31-560
  Headlights, adjusting against wall or screen
  Heater and air control 83-75
  Heating system 83-50
  Hitch 6×6 71-275
  Hitch 71-250
  Hoist cylinder 91-250
  Hoses over hitch 6×6 51-190
  Housing,covers and boltings 41-150
  Hub reduction, installing
  Hub reduction, removing
  Hydraulic brake system Tractor 51-200
  Hydraulic cooling fan control, PC test
  Hydraulic lines and valve 41-300
  Hydraulic oil tank 91-100
  Hydraulic oil tank, oil, replace if system is filled with mineral oil or Volvo Biodegradable hydraulic oil 46. If system is filled with other biologically degradable hydraulic oil, replace every 2000 hour.
  Hydraulic pump 61-200
  Hydraulic system 91-50
  Hydraulic system, trailer6x6 91-75
  I-ECU, MID 140, changing non-Programd ECU 1
  I-ECU, MID 140, changing non-Programd ECU
  I-ECU, MID 140, changing pre-Programd ECU
  IEGR, double rocker arms adjustment, check. OBS! Only at first 1000 hours. Following checks are made at intervals for valve adjustment.
  Induction sensor for turbine speed, changing
  Information on Bio-diesel fuel (RME-fuel)
  Information on classification of oils
  Injection pump 23-250
  Injector 23-450
  Injectors, replacing copper sleeve in machine
  Inlet system 24-50
  Instrument panel and cover plates Tillv Nr -59471
  Instrument panel tillv nr – 59471 31-750
  Instrument panel tillv nr 59472 – 31-775
  Intercooler, replacing
  Intermediate shaft and or bearing, replacing (in frame joint)
  Lap belts
  Large-volume horn 98973 (6282) 31-650
  Lighting,tractor 31-350
  Lighting,trailer 31-450
  Load and dump brake, working pressure, checking and adjusting
  Load body, rubber cushions, clearance, check
  Lock-up clutch tillv nr – 59407 41-650
  Lubricant, Biodegradable Hydraulic Fluid
  Lubricating oil system 21-350
  Lubrication oil pressure, checking with pressure gauge
  Lubrication, see lubrication chart
  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
  MATRIS, Electronic Control Unit
  More than one document matches choosen profile 1
  More than one document matches choosen profile 2
  More than one document matches choosen profile
  New coolant
  New tipping cylinders
  New Volvo standard for transmission oil
  New warranty routines for Bosch diesel equipment
  Oil cooler 22-250
  Oil cooler, replacing 1
  Oil cooler, replacing
  Oil filter 41-450
  Oil level sensor, changing
  Oil pump 21-400
  Oil sampling, method
  Oil sump gasket, changing
  Oil-bath air cleaner’s reservoir (optional equipment), clean, and oil, change
  Oil-bath air cleaner’s reservoir (optional equipment), filter insert, clean
  Oil-bath air cleaner’s reservoir (optional equipment), oil, check
  Operator’s seat 1
  Operator’s seat
  Output shaft 6-wheel drive bearing, replacing
  Parking brake , replacing brake caliper
  Parking brake pads, check
  Parking brake valve 51-850
  Parking brake, basic check
  Parking brake, function check
  Parking brake, replacing brake disc
  Parking brake, replacing brake pads
  Parking brake, replacing
  Planet shaft ah 54 k 6×6 44-85
  Planet shaft ah 54d 6×6 44-95
  Pneumatic cylinder 24-400
  Pneumatic cylinder 41-750
  Pneumatic cylinder tilt limiting 91-300
  Pneumatic system for operation of controls Serial No. – 59471 41-550
  Pneumatic system for operation of controls Serial No. 59472 – 41-575
  Pneumatic system for operation of Differential 42-125
  Pneumatic system, trailer6x6 41-600
  Power shafts with fitting parts 6×6 43-75
  Power take-off 42-300
  Power take-off suction strainer, cleaning
  Power take-off with fitting parts and Controls 42-200
  Power take-off, between engine and gearbox, reconditioning
  Power transmission 41-50
  Power transmission, basic check
  Pree cleaner, oilbath 98986 (6458) 24-125
  Preheating coil, replacing
  Propeller shaft 43-200
  Propeller shaft 43-225
  Propeller shaft, trailer 6×6 43-85
  Propeller shafts with fitting parts 43-50
  Protecting plate, installation
  Protecting plate, removal
  Quality of illustrations in technical reports
  Quick coupling compressed air, replacing
  Radiator 22-100
  Radiator, adjusting
  Radiator, clean (from fan side with compressed air)
  Radiator, installation
  Radiator, removal
  Range selector controls 41-500
  Range selector valve 41-350
  Rear bogie axle suspension 6×6 72-250
  Rear flap, mechanical 98491
  Recommendations for changing injectors
  Reduction gear 6×6 43-175
  Reduction gear 43-150
  Regulator control 25-50
  Relay panel 31-800
  Relay valve 51-700
  Relief Cut-in pressure, adjusting
  Relief Cut-in pressure, check
  Repair kit, part no. 11666145, for service display
  Reporting of accidents and incidents
  Reporting of product misuse & near-miss report
  Routine for return of technical goods
  Rubber cushion, replacing
  Seal for rear output shaft, replacing
  Service brake, brake pads, check
  Signal lantern with revolving light 98974 (6310) 31-600
  Smoke limiter 23-380
  Smoke limiter 23-375
  Spindle, replacing one side
  Spring brake cylinder, replacing
  Spring-brake cylinder 51-800
  Stall speed, checking
  Starter motor 31-250
  Starter motor, replacing
  Starting heater 21-450
  Starting heater 21-500
  Steering and hydraulics, basic check
  Steering angle, checking and adjusting
  Steering cylinder 61-300
  Steering cylinder bearings, clearance, check
  Steering cylinder removed, reconditioning excl replacing bearings
  Steering cylinder, installation
  Steering cylinder, removal
  Steering gear with fitting parts
  Steering gear, check.and adj.
  Steering gear, replacing
  Steering gear
  Steering joint bearings, first check of steering joint bearings after 6000 hours. Thereafter every 2000 hours.
  Steering linkage, checking and adjusting 1
  Steering linkage, checking and adjusting
  Steering system 61-50
  Steering times, checking and adjusting
  Steering valve, neutral position, checking and adjusting
  Sun vizors and rear view mirrors 82-100
  Tail light with bracket 6×6 31-475
  T-ECU, MID 130, changing pre-Programd ECU 1
  T-ECU, MID 130, changing pre-Programd ECU
  Test-run and check
  Thermostat, replacing
  Timing gear casing,timinggears and engine-speed Indicator 21-250
  Tools, tools for removing cable terminals
  Torque converter 6×6 41-135
  Torque converter tillv nr – 59407 6 X 4 41-100
  Torque converter tillv nr 59408 – 6 X 4 41-125
  Trailer frame 6×6
  Trailer frame and trailer body 71-200
  Trailer frame and trailer body 71-235
  Transmission pump 41-400
  Transmission, installing
  Transmission, oil, main oil filter and lubrication oil filter, replace.
  Transmission, removing
  Transverse differential lock axle, checking and adjusting
  Turbo charger 24-250
  Turbocharger with fitting parts 24-200
  Turbocharger, inspection
  Turbocharger, replacing
  Tyres, various types
  Tyres, wear and air pressure, checking
  Unit injector, replacing
  Unit injectors, adjusting pretension
  Universal joint brake 6×6 51-350
  Valve adjustment
  Valve clearance and IEGR, double rocker arms, check adjust
  Valves, adjusting
  V-ECU, MID 187, changing pre-Programd ECU 1
  V-ECU, MID 187, changing pre-Programd ECU
  Volvo-Catalog
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Water pump 22-200
  Water pump with fitting parts 22-150
  Wheel equipment 6×6 42-425
  Wheel equipment 42-500
  Wheel equipment, tractor 42-400
  Wheel equipment, tractor 42-450
  Wheel equipment, trailer 6×6 44-350
  Wheel equipment, trailer SER NO – 59094
  Wheel hub 42-350
  Windscreen wiper front, replacing motor
  Windshield wiper and signal horn 31-400

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