Complete repair service manual with electrical wiring diagrams for Articulated Haulers A25C Volvo / A25C Volvo BM / A25C Volvo 4x4 / A25C Volvo 4x4 BM, with technical information to maintain, diagnose, repair, and service like professional mechanics.

Articulated Haulers A25C Volvo / A25C Volvo BM / A25C Volvo 4x4 / A25C Volvo 4x4 BM 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.

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

PRODUCT DETAILS:
Pages: 1,170
File Format: PDF (Windows & Mac & Linux)
Language: English
...
TABLE OF CONTENTS
0 - Foreword.......2
0 - GENERAL.......3
  00 - DESCRIPTION; COMPLETE MACHINE.......4
    Description-[3028].......4
    Product identification plates.......5
  03 - SPECIFICATIONS.......6
    Brakes.......6
    Electrical system.......9
    Engine.......12
    Hydraulic system.......15
    Power transmission-.......17
    Specifications, capacities-.......21
    Specifications, change intervals.......22
    Specifications, dimensions.......23
    Specifications, tightening torques].......25
    Specifications, weights .......36
    Steering system.......38
    Volvo standard tightening torques.......39
  07 - STANDARD TIME.......41
    Time Guide.......41
  08 - TOOL.......50
    Drawings of E-tools that can be made in your own workshop.......50
    Recycling station FRS-10GS.......63
    Special tools for the drivetrain.......65
1 - STANDARD PARTS, SERVICE.......69
  16 - LUBRICANT; FUEL; OTHER FLUID.......70
    Brake system, changing brake fluid.......70
    Recommended lubricants.......72
  17 - SERVICE.......74
    Cleanliness, hydraulic systems.......74
    Electric welding.......75
    Repairs of hydraulic systems.......76
    Towing.......77
2 - ENGINE WITH MOUNTING AND EQUIPMENT.......80
  21 - ENGINE.......81
    Compression check, engine at operating temperature.......81
    Description.......84
    Engine and transmission, mounting.......85
    Engine and transmission, removing.......89
    Engine, mounting.......98
    Engine, removing.......102
    Specifications, capacities-[1855].......110
    Specifications, general-[1633].......111
    Specifications, general-[1810].......112
    Specifications, tightening torques-[1423].......113
    Specifications, tightening torques-[1451].......116
    Specifications, tightening torques-[1536].......117
    Specifications, tightening torques-[1550].......118
    Specifications, tightening torques-[1657].......119
    Specifications, tightening torques-[1721].......120
    Specifications, tightening torques-[1750].......121
    Specifications, tightening torques-[1841].......122
    Specifications, weights-[1823].......124
    Valves, adjusting.......125
  22 - LUBRICATING SYSTEM.......127
    Lubrication oil pressure, checking.......127
    Specifications, general-.......129
    Specifications, general-[1304].......130
  23 - FUEL SYSTEM.......131
    Automatic timing adjuster (alpha adjuster).......131
    Automatic timing adjuster, checking.......132
    Fuel feed pump, checking feed pressure.......138
    Fuel injection pump, changing incl. setting injection timing.......140
    Fuel system, bleeding.......146
    Idle speed, checking and adjusting.......148
    Injection timing TDC, checking and adjusting.......150
    Injection timing, checking.......155
    Injectors, changing all.......159
    Low and high idle speed, checking and adjusting with service display unit.......163
    Low emission engines.......166
    Specifications, capacities-[1054].......168
    Specifications, general-[0643].......169
    Specifications, general-[0814].......170
    Specifications, general-[1118].......171
    Specifications, tightening torques-[0657].......172
    Specifications, tightening torques-[0828].......173
    Stall speed, checking with service display unit.......174
    Stall speed, checking.......176
  25 - INLET & EXHAUST SYSTEM.......177
    Specifications, general-[0357].......177
    Specifications, general-[0422].......178
    Specifications, tightening torques-[0446].......179
  26 - COOLING SYSTEM.......180
    Coolant filter, changing-[0236].......180
    Coolant filter, changing.......182
    Coolant, changing.......184
    Description-[0327].......187
    Fan motor, changing piston rings.......191
    Hydraulic motor for fan, alternatively hydraulic pump, checking internal leakage.......197
    Radiator fan drive, checking function of motor.......199
    Radiator fan drive, general description.......201
    Radiator fan motor, adjusting speed.......203
    Radiator, changing.......205
    Specifications, capacities-[0306].......207
    Specifications, general-[0250].......208
    Specifications, general-[5932].......209
    Thermostat valve (removed), reconditioning.......211
    Thermostat valve, checking function.......213
    Thermostat valve, description.......214
  27 - ENGINE CONTROL.......215
    Throttle pedal, anti-throttle cylinder, adjusting.......215
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.......217
  30 - GENERAL.......218
    Description-[5746].......218
    Electrical symbols.......219
    Fuses.......223
    Special instructions for servicing the electrical system.......238
    Specifications, general-[5619].......239
  31 - BATTERY.......240
    Charging of batteries.......240
    Specifications, general-[5535].......241
  32 - ALTERNATOR; CHARGE REGULATOR.......242
    Alternator, changing.......242
    Charging, checking in machine (multimeter).......244
    Specifications, general-[5410].......249
    Specifications, general-[5424].......250
  33 - STARTING SYSTEM.......251
    Specifications, general-[5342].......251
    Starter motor, changing.......252
  35 - LIGHTING.......255
    Headlight, complete, changing 1 headlight incl. adjusting alignment.......255
    Headlights, adjusting against wall or fender.......256
    Specifications, general-[5243].......257
  37 - CABLE; FUSE; RELAY.......258
    A25C 4x4 turn-around wheels (serial no. –12483).......258
    Circuit 14–36-[5024].......260
    Circuit 14–36.......264
    Circuit 37a–37e-[4909].......268
    Circuit 37a–37e.......271
    Circuit 37f–37I-[4840].......274
    Circuit 37f–37I.......278
    Circuit 38–53A-[4800].......282
    Circuit 38–53A.......285
    Circuit 53B–75-[4722].......289
    Circuit 53B–75.......293
    Circuit 66 and 77-[4648].......297
    Circuit 66 and 77.......300
    Circuit 76–89-[4610].......303
    Circuit 76–89.......307
    Circuit 7–13-[5101].......311
    Circuit 7–13.......315
    Circuit 90–91.......319
    Circuit 90–93.......322
    Circuit 94–98.......325
    Circuit board, right electrical distribution box-[3248].......328
    Circuit board, right electrical distribution box.......329
    Circuit index.......330
    Code legend for connectors-[4111].......333
    Code legend for connectors.......410
    Codes in wiring diagrams.......489
    Explanations of wiring diagrams.......490
    Fuses, left electrical distribution box-[3210].......492
    Fuses, left electrical distribution box.......494
    Fuses, right electrical distribution box-[3142].......496
    Fuses, right electrical distribution box.......499
    Instrument panel, (serial no. 11101–, BR 70301–, US 66 61401–, 44 68201–).......503
    Instrument panel, (serial no. –11100, BR –70300, US 66 –61400, 44 –68200).......505
    Other fuses.......507
    Relays, left electrical distribution box-[3038].......509
    Relays, left electrical distribution box.......511
    Relays, right electrical distribution box-[3010].......514
    Relays, right electrical distribution box.......516
    Specifications, general-[2936].......519
    Template for pin numbers connector X1_A1.......520
    Wiring diagrams (serial no. –11100, BR –70300, US 66 –61400, 44 –68200) Circuit 0–6.......522
    Wiring diagrams(serial no. 11101–, BR 70301–,.......525
  38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.......527
    Connection.......527
    Contronic Information Display Unit.......528
    Contronic service display unit.......530
    ECU, reading off with measuring instrument.......532
    Information display unit, summary.......534
    Information on the information display unit.......535
    Information on the service display unit-[2413].......540
    Information on the service display unit.......552
    Load sensor, adjusting.......561
    Load sensor, checking electric circuits.......563
    Measuring instrument, summary.......565
    Service display unit, summary.......566
    Specifications, general-[2622].......567
    Specifications, general-[2920].......568
    Speedometer, changing-[2857].......569
    Speedometer, changing.......571
    Speedometer, electric, calibrating.......573
    Speedometer, electronic, description.......575
    Speedometer, electronic.......579
    Using the service display unit.......584
4 - POWER TRANSMISSION.......585
  40 - GENERAL.......586
    Description-[2125].......586
    Power transmission.......588
  41 - CLUTCH; TORQUE CONVERTER.......589
    Specifications, tightening torques-[2043].......589
  42 - TRANSMISSION; HYDRAULIC CONTROL.......590
    Control system, changing.......590
    Diagnosis using error codes on service display unit.......594
    Functional description, transmission.......596
    Gearshift selector, checking.......597
    Hydraulic diagram, transmission with retarder-[1950].......599
    Hydraulic diagram, transmission with retarder.......602
    Hydraulic transmission, checking oil pressure.......605
    Inductive sensor for output shaft, changing.......609
    Inductive sensor for turbine speed, changing.......612
    Oil cooler, changing.......617
    Safety functions.......620
    Seal for rear output shaft, changing.......621
    Solenoids, checking resistance.......625
    Specifications, capacities-[1446].......627
    Specifications, general-[1420].......628
    Specifications, general-[1913].......629
    Specifications, weights-[1433].......630
    Transmission PT1051 – cut-away drawing.......631
    Transmission PT1051, general description.......632
    Transmission functions, checking instructions for connector X1_A1.......633
    Transmission, general troubleshooting.......638
    Transmission, mounting(downward).......639
    Transmission, removing and mounting (together with engine).......642
    Transmission, removing and mounting.......649
    Transmission, removing(downward).......652
    Troubleshooting chart, transmission.......659
    Troubleshooting chart.......661
    Troubleshooting outside the control unit in connector X1_A1.......666
    Troubleshooting.......668
    Wiring diagram, transmission electronics, circuit 37a-I.......669
  43 - GEARBOX.......672
    Dropbox FL 652 C, general description.......672
    Dropbox FL652C.......673
    Dropbox, adjusting high and low range.......674
    Dropbox, changing compressed air cylinder for high and low range.......678
    Dropbox, changing seal for front.......680
    Dropbox, changing seal for input shaft.......683
    Dropbox, changing seal for rear.......686
    Dropbox, mounting.......689
    Dropbox, removing.......691
    Longitudinal differential lock, adjusting engagement.......696
    Specifications, capacities-[0949].......700
    Specifications, general-[0908].......701
    Specifications, tightening torques-[0936].......702
    Specifications, weights-[0921].......703
  45 - PROPELLER SHAFT.......704
    Intermediate propeller shaft and_or bearing, changing (in frame joint).......704
    Propeller shaft between transmission and.......712
    Propeller shaft for front bogie axle, changing.......715
    Propeller shaft for rear bogie axle, changing.......717
    Propeller shaft in frame joint, changing.......719
    Propeller shaft, front output shaft on dropbox, changing.......720
    Specifications, tightening torques-[0837].......721
  46 - FRONT AXLE; REAR AXLE.......723
    Dog clutch 66, checking and adjusting.......723
    Drive axles AH54 and AH56H.......727
    Final drive 66 output shaft, changing.......728
    Front axle complete, removing.......732
    Hub, changing seals (one side).......736
    Specifications, capacities-[0530].......750
    Specifications, general-[0314].......751
    Specifications, general-[0447].......752
    Specifications, tightening torques-[0517].......754
    Specifications, weights-[0501].......756
    Transverse differential lock, adjusting.......757
  48 - POWER TAKE OFF.......761
    Flywheel housing (rear engine transmission).......761
    Power take-off in flywheel housing, changing.......762
    Power take-off in flywheel housing, reconditioning.......764
    Specifications, general-[0121].......773
    Specifications, general-[0227].......774
5 - BRAKE.......775
  50 - GENERAL.......776
    Description-[5516].......776
    Specifications, general-[5401].......778
  51 - WHEEL BRAKE.......779
    Brake caliper, changing (per caliper).......779
    Brake caliper, reconditioning.......783
    Brake disc for service brake, checking.......786
    Brake disc, changing.......788
    Brake pads for service brake, checking.......802
    Brake pads, changing (one wheel).......804
    Specifications, tightening torques-[5227].......810
    Specifications, weights.......811
  52 - HYDRAULIC BRAKE SYSTEM.......812
    Brake system, bleeding.......812
    Description.......815
    Foot brake valve.......818
    Specifications, capacities-[3737].......823
  55 - PARKING BRAKE.......824
    Blocking valve for parking brake.......824
    Parking brake caliper removed, reconditioning.......826
    Parking brake valve – hand-operated lever.......828
    Parking brake valve, reconditioning.......832
    Parking brake, changing brake caliper.......836
    Parking brake, changing brake disc.......840
    Parking brake, changing brake pads.......843
    Parking brake.......846
    Specifications, general-[2951].......847
    Specifications, general-[3117].......848
    Specifications, tightening torques-[3148].......849
    Spring brake cylinder removed, reconditioning.......850
    Spring brake cylinder, changing.......853
  56 - COMPRESSED-AIR BRAKE.......855
    Air compressor.......855
    Air-hydraulic unit.......856
    Anti-freeze (air-freeze) reservoir.......857
    Automatic adjustment lever.......859
    Blocking valve, reconditioning (removed).......860
    Compressor, changing.......862
    Cut-out and cut-in pressures, checking and adjusting.......865
    Foot brake valve, reconditioning (removed).......867
    Four-way pressure retaining valve, reconditioning (removed).......871
    Four-way pressure retaining valve.......873
    Pressure regulator.......877
    Relay valve, reconditioning.......879
    Relay valve.......881
    Safety valve, wet tank.......884
    Specifications, capacities-[2256].......885
    Specifications, capacities.......886
    Specifications, general-[2112].......887
    Specifications, general-[2218].......888
    Specifications, general-[2646].......889
    Specifications, general.......890
    Specifications, tightening torques.......891
    Spring brake cylinder.......892
  59 - MISCELLANEOUS.......894
    Compressed air diagram A25C - Image.......894
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. 11101–, BR 70301–, US 66 61401 –, 44 68201–) - Image.......896
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. 11101–, BR 70301–, US 66 61401 –, 44 68201–)-[1810].......897
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. 11101–, BR 70301–, US 66 61401 –, 44 68201–)-[1826].......900
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. 11101–, BR 70301–, US 66 61401 –, 44 68201–)-[1842].......903
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. 11101–, BR 70301–, US 66 61401 –, 44 68201–).......906
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. –11100, BR –70300, US 66 –61400, US 44 –68200) - Image.......909
    Compressed air diagram A25C, 4x4 turn-around wheels (serial no. –11100, BR –70300, US 66 –61400, US 44 –68200).......910
    Compressed air diagram A25C.......913
    Compressed air diagram A25CTS 6x6 - Image.......915
    Compressed air diagram A25CTS 6x6-[1734].......917
    Compressed air diagram A25CTS 6x6.......920
    Functional description, hydraulic retarder.......921
    Retarder circuit.......923
6 - STEERING.......925
  60 - GENERAL.......926
    Description, steering system.......926
    Specifications, general.......929
  64 - STEERING.......930
    Damping cylinder, changing seals.......930
    Damping cylinder, checking pre-load.......933
    Damping cylinder, removing and mounting.......935
    Damping cylinder.......937
    Pressure accumulation, engine dependent pumps 1 and 2.......938
    Specifications, general .......941
    Specifications, general-.......942
    Specifications, general.......943
    Specifications, weights-.......944
    Steering cylinder bearing, checking.......945
    Steering cylinder, changing spherical bearing.......947
    Steering cylinder, changing.......949
    Steering cylinder, reconditioning in machine (left steering cylinder).......952
    Steering cylinder.......955
    Steering gear, changing.......956
    Steering gear, checking and adjusting.......960
    Steering linkage, changing roller bearing in front lever.......963
    Steering linkage, changing roller bearings in rear lever.......974
    Steering linkage, checking and adjusting.......980
    Steering system, checking and adjusting operating pressure.......983
    Steering valve neutral position and valve slide.......985
    Steering valve removed, reconditioning.......988
    Steering valve, changing.......992
    Steering valve.......996
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.......999
  71 - FRAME.......1000
    Description.......1000
    Load unit frame, checking dimensions.......1002
    Specifications, tightening torques-.......1004
    Specifications, weights-.......1007
  72 - SUSPENSION.......1008
    Front rubber springs, changing all.......1008
    Suspension.......1012
  74 - FRAME LINK.......1013
    Frame joint, changing hitch.......1013
    Frame joint, changing metallic bearing.......1015
    Frame joint, checking and adjusting clearance.......1023
    Frame joint, separating and assembling.......1026
    Specifications, tightening torques.......1032
    Specifications, weights-.......1033
    Steering joint and frame joint.......1034
    Steering joint, changing spherical bearings.......1036
    Steering joint, checking clearance.......1047
  75 - AXLE SUSPENSION.......1049
    A-frame rubber bushing brackets, adjusting front bracket.......1049
    Bogie beam, changing rubber bushing (one side).......1050
    Bogie beam, changing rubber springs.......1054
    Front axle, changing rubber spring (bushing).......1056
    Front or rear bogie axle torsion bar, adjusting.......1059
    Load unit A-frame, changing rubber spring (bushing).......1060
    Torsion bar and_or rubber bushing, changing on load unit.......1062
    Torsion bar, checking and adjusting.......1064
  77 - WHEELS; TRACKS; TYRE; HUB; DRUM.......1068
    Specifications, weights-.......1068
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.......1069
  81 - CAB, NAKED; CANOPY.......1070
    Specifications, weights.......1070
  84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING.......1071
    Window pane, changing.......1071
  85 - CAB INTERIOR; UPHOLSTERY.......1073
    Air spring for operator’s seat, changing.......1073
    Maintenance instructions.......1075
    Operator’s seat, adjusting height of attachment.......1076
    Operator’s seat, air suspension.......1077
    Operator’s seat, mechanical suspension.......1078
  87 - AIR CONDITIONING UNIT.......1079
    Air conditioning, checking function.......1079
    Fan motor, changing.......1080
    Filling refrigerant R134a.......1083
    Functional description.......1087
    Heat control valve, changing.......1089
    Heater, changing.......1091
    Protection against electromagnetic interference.......1093
    Refrigerant R134a, draining.......1095
    Specifications, general .......1098
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.......1099
  90 - GENERAL.......1100
    Description.......1100
    Pressure check connection on hydraulic system.......1101
  91 - WORKING HYDRAULIC; SERVO HYDRAULICS.......1103
    Hydraulic pumps, functional description.......1103
    Hydraulic system and component positions.......1113
    Hydraulic system, bleeding air.......1115
    Internal leakage, checking.......1116
    Oil pump, changing ground dependent pump.......1118
    Oil pump, checking and adjusting hold (standby) pressure.......1120
    Specifications, capacities-[3827].......1123
    Specifications, capacities.......1124
    Specifications, general-[3538].......1125
    Specifications, general-[3704].......1126
    Specifications, general-[3728].......1127
    Specifications, general-[3814].......1128
    Troubleshooting charts-[3801].......1129
    Troubleshooting charts.......1130
  95 - LOAD CARRIER.......1131
    Adjusting shims, checking and adjusting lateral position.......1131
    Dump lever, adjusting.......1133
    Dumping system, description.......1134
    Dumping valve, changing cable.......1142
    Dumping valve, changing.......1144
    Hoist cylinder removed, reconditioning.......1146
    Hoist cylinder, changing.......1150
    Installing piston rod seals.......1153
    Load and dump brake.......1155
    Load body position indicator, adjusting.......1156
    Load body, adjusting against frame.......1157
    Load body, changing dump bearing.......1159
    Specifications, general.......1163
    Specifications, weights.......1164
  99 - MISCELLANEOUS.......1165
    Hydraulic diagram A25C 4x4 with turn-around wheels - Image.......1165
    Hydraulic diagram A25C 4x4 with turn-around wheels.......1166
    Hydraulic diagram A25C 6x6 - Image.......1168
    Hydraulic diagram A25C 6x6.......1169

Articulated Haulers A25C Volvo / A25C Volvo BM / A25C Volvo 4x4 / A25C Volvo 4x4 BM Service Repair Manual