Service Information Document Title: Function Group: Appointment and 091 distribution of responsibility
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
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A25D Volvo
WARNING No changes may be made to the electrical system without prior approval from Volvo. Changes may affect machine functions and can result in risks for personal injury or machine damage. Volvo Articulated Haulers AB gives only recommendations for retrofitting based on the characteristics and properties of Volvo chassis and that Volvo Articulated Haulers AB can determine prior to retrofitting without knowledge of the specific case involving retrofitting. Therefore, the responsibility for the retrofit and its compliance to issued requirements rests with those performing the retrofitting. This also applies to the responsibility for the entire vehicle’s characteristics and properties to the extent that they are affected by the retrofit. This includes requirements from authorities as well as general suitability and safety requirements. The dealer/retrofitter is responsible to the customer with regards to giving sufficient instructions about functions and care of the retrofitted equipment and modification of chassis. When a complete vehicle is sold, the dealer is responsible to the customer that the retrofitted equipment has been installed according to the requirements and retrofitting instructions from Volvo Articulated Haulers AB. In case of eventual retrofitting work that cannot contain already known requirements or there are any other doubts, contact Volvo Articulated Haulers AB, Special Vehicles department. The stability may be affected following any and all changes to the basic product. For example, this applies when load body sides are heightened. When special equipment is retrofitted, the instructions in the specification section must be followed. This is especially important in order to maintain the center of gravity within the specified range, both vertically and horizontally. All welding should be performed according to ISO 5817, welding class C. NOTE! No modification of the machine’s hydraulic system is allowed without consent from Volvo Articulated Haulers AB, Special Vehicles department.
Service Information Document Title: Basic check, transmission
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
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A25D Volvo Purpose of the basic check The purpose of the basic check is to provide fast and accurate information about the general condition of the transmission. The normal work procedure is to perform the basic check following collection of basic data, reading out error codes and checking parameters, if it has not been possible to determine the cause of the malfunction up to that point. The basic check's tests should be run and evaluated according to instructions in Tech Tool. Tests included in the basic check The first step in the basic check is to operate the machine, to test-run the vehicle. The basic check is then divided into the following tests, which should be performed in the order that they are listed, after reading out error codes, checking parameters and operating (test-running)the machine. Tests: 1. 2. 3. 4.
Op no. 40012-3, Position sensor, gearshift selector, testing The test is used to check that the selected gear position is correctly read in the control unit. Op no. 40025-3, Solenoid valves, testing The purpose of the test is to check that all solenoid valves work. Op no 40098-3, Gears, checking oil pressure, testing The purpose of the test is to check the pressure to brakes and clutches in the transmission. Op no 40027-3, PWM-valves, main and brake pressure, testing The purpose of the test is to check the function of the PWM valves.
Service Information Document Title: Basic checks
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Basic checks Showing Selected Profile Valid for serial numbers Model
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A25D Volvo NOTE! Basic data must always be collected and error codes and parameters must always be checked before the basic check is started; see Troubleshooting, general. Basic check is performed on each main system. The purpose of the basic check is that it shall give quick and certain information about the status in the sub-system included in each main system. Each basic check is divided into a number of checks to be performed in order. If the basic check does not help to locate the cause of the malfunction, the information obtained helps as guidance for continued troubleshooting together with other service information. The basic check(s) to be performed is determined by the information obtained when the basic data was collected; see Collection of basic data. Basic checks: Engine, basic check Electrical system, basic check Power transmission, basic check Brake system, basic check Parking brake, basic check Steering and hydraulics, basic check
Service Information Document Title: Collection of basic data
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Collection of basic data Showing Selected Profile Valid for serial numbers Model
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A25D Volvo The first step in all troubleshooting work is collection of basic data to quickly get a good picture of how the problem manifests itself.
Figure 1 In addition to information about machine and customer, it is important to get as much information as possible about events in connection with the occurrence of the malfunction. The operator can often provide valuable information on the prevailing circumstances when the malfunction occurred since the operator is almost always the first to detect a problem. Often, the malfunction or perceived problems are difficult to recreate if the circumstances are not exactly the same. In these instances in particular, the information from the operator is vital to being able to make correct assessments when continuing troubleshooting. Use the questions below to interview the operator. Note the responses to the questions and save them together with the work order. General data Customer information Dealer information The operator Machine specifications: Machine
Serial number Part number of software in control units
Figure 2 Figure part number software, information display unit Machine hours Engine type Engine number Delivery date Transmission type Transmission number Problem description Have any error codes been generated? Describe the malfunction. When did the malfunction occur? How was the malfunction detected and what happened just before it was noticed? Does the malfunction reappear? How often does the malfunction occur? How long does the malfunction last when it occurs? Does the malfunction always occur during the same conditions, if so, what are they? Does the operator have an idea of what may be the probable cause of the malfunction? Does the problem still exist? Engine data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? Is the engine difficult to start? Is there abnormal smoke development? Are there abnormal engine sounds? Have changes in fuel consumption, oil consumption or power been confirmed? What type of fuel is used? Are additives used in the fuel? If yes, which ones? What repairs or other work has been performed on the engine? Other information? Power transmission, data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? Is there a difference in rolling circumference between the tires that is greater than 1.5%? Other information? Brake system, data Under what operating conditions does the malfunction occur?
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External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? When was the last oil filter change? Is there abnormal heat generation from one or several wheels? Other information? Steering and hydraulics, data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? When was the last oil filter change? Other information?
Service Information Document Title: Function Group: Coolant with freezing and 030 corrosion protection
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Coolant with freezing and corrosion protection Showing Selected Profile Valid for serial numbers Model
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A25D Volvo Anti-freeze Check the anti-freeze every 500 hours. At delivery, the cooling system is filled with a mixture of 50% water and 50% Volvo Construction Equipment concentrated coolant with freezing protection down to -25°C. If there's a risk that the ambient temperature drops below this temperature, the freezing protection should be adjusted, see below. Corrosion protection Volvo Construction Equipment concentrated coolant contains active corrosion protection additives to protect engine and radiator. These additives have a limited service life. Therefore, change the coolant every 3000 hours. NOTE! Volvo Construction Equipment concentrated coolant may not be mixed with other brands of coolant or additives. Mixing could have negative effects. Volume and change volume cooling system; see Engine, capacities. The content of concentrated coolant with anti-freeze protection may not be below 40%. 40% provides protection against freezing down to -25° C. 50% provides protection against freezing down to -37° C.
Service Information Document Title: Dealers/retrofitter´s responsibility
Function Group: 091
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Dealers/retrofitter´s responsibility Showing Selected Profile Valid for serial numbers Model
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A25D Volvo It is important that both Volvo Articulated Haulers’ retrofitting instructions and national legal legislation is followed when retrofitting and modifying Volvo chassis.
Service Information Document Title: Hydraulics
Function Group: 000
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Hydraulics Showing Selected Profile Valid for serial numbers Model
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A25D Volvo HYDRAULICS The following information is displayed on the unit: Engine dep. xxx bar
Shows hydraulic oil pressure from engine-dependent pumps in bar/psi.
Ground dep. xxx bar
Shows hydraulic oil pressure from ground-dependent pump in bar/psi.
Figure 1 HYDRAULICS, all languages VOLVO CONTRONIC - - - HYDRAULICS - - Engine dep.
xxx
bar
Ground dep.
xxx
bar
HYDRAUL TANK VALVE NOTE! The valve is discontinued on machines of later version, see SE9101, Wiring diagram A24. See also 35F9901 Parameters, MO21 module start–stop. The following information is displayed on the unit:
Closed no start Activated Deactivated The key is used to shift between activated and not activated.
Figure 2 HYDRAUL TANK VALVE VOLVO CONTRONIC HYDRAUL TANK VALVE Closed not start Enabled
*
Service Information Document Title: Information and decals
Function Group: warning 000
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
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A25D Volvo The operator should be aware of and follow the information and warning decals that are located on the machine. All decals are not found on all machines, since they are market-dependent and machine-dependent. The decals shall be kept clean and legible. If decals have been lost or no longer are readable, they shall be replaced immediately. Spare part number (order number) is stated on each decal as well as in the Parts catalogue. NOTE! The text “WARNING” is shown on the warning decals in North America.
Figure 1
1. Attaching point for lashing
2. Battery disconnect switch
3. Avoid spraying water at air inlets.
4. Retarder diagram
6. Air conditioning filled with R134a. Opening pressure safety
5. WARNING! Do not operate downhill with the gear selector valve (optional equipment) in N-position. Only shift gears with the gas pedal let up.
7. WARNING! Do not use the overhung tailgate (optional equipment) if there is any risk that it can block the load when 8. Emergency exit dumping. Accidents as a result of the machine turning over or the ground giving way can cause personal injuries and machine damage.
9. WARNING! Risk of crushing – frame steering
10. WARNING! Do not enter the work area of a reversing machine
Figure 2
11. WARNING! Rotating fan
12. WARNING! Do not lean in under a raised load body without first securing it.
13. Pressurized brake system
14. Tire pressure
15. Hydraulic oil
16. Fuel
17. WARNING! Only use genuine Volvo coolant VCS – read the Operator's Manual
18. Engine hood
19. Sound pressure level (LpA) at operator's station
21. Service decal
20. Sound power level (LwA) around the machine
Service Information Document Title: Lifting machine
Function Group: 050
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Lifting machine Showing Selected Profile Valid for serial numbers Model
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A25D Volvo
WARNING Never stand under the machine when it is suspended in the air. 1.
Lock the steering joint with the steering joint lock.
2. 3. 4.
Figure 1 Steering joint lock Block the rear wheels. Release the parking brake and disengage the differential locks. Lift the machine by the front lifting eyes in the frame.
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Figure 2 5.
Turn the front wheels so that the lifting eyes on the wheels are positioned as shown in the adjacent figure.
Figure 3
WARNING Do not lift the machine by the load body eyes. 6. 7.
Block the front wheels. Place a lifting sling or strap under the rear end (chute) of the load body.
Figure 4 8.
Turn the front bogie wheels so that the lifting eyes on the wheels are positioned as shown in the adjacent figure.
Figure 5 9. 10.
Lower the machine. Apply the parking brake.
WARNING The distance between the lifting hook and the wheels' lifting eyes must be at least 8.5 metres. 11.
Lift the machine by the lifting eyes on the wheels.
Figure 6 12. 13.
Lower the machine. Disconnect the steering joint lock before the machine is operated.
Service Information Document Title: Recovering and towing
Function Group: 050
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Recovering and towing Showing Selected Profile Valid for serial numbers Model
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A25D Volvo
WARNING Before starting any recovery or towing work, make sure that the parking brake is applied and the wheels are blocked to prevent the machine from rolling. Extreme caution must be observed in connection with towing to prevent accidents and personal injuries.
WARNING If the engine cannot be started, the brake and steering functions will be severely limited. In such cases, towing should only be performed in an emergency situation by experienced and trained personnel and only for the shortest possible distance (see towing). If possible, transport the machine on a trailer. General If possible, the engine should be running while recovering/towing the machine to ensure satisfactory braking and steering performance. Recovering Use a towbar, heavy-gauge cable or chain connected to the towing eyes at the front or rear of the machine to tow the machine to a suitable place or passable road. Towing If the machine has to be towed to a workshop after recovery, use a towbar or heavy-gauge towing cable connected to the front towing eyes. A towbar must always be used if the machine that is to be towed has no brake function. The towing vehicle or machine must always be at least as heavy as the towed machine and have sufficient engine and braking power to tow and brake both machines on uphill and downhill grades. Always tow the shortest possible distance. Maximum towing speed under all conditions is 10 km/h. NOTE! The engine cannot be started by towing the vehicle. Case 1 (with engine running) The gearshift selector should be in neutral and the parking brake in the operating position. The machine can be towed for 10 km without taking special action.
Case 2 (without engine running) Since the transmission is not lubricated when the engine is not running, the propeller shaft between the transmission and dropbox shall be removed. Then lubrication to the dropbox is maintained at the same time as the machine can be steered. Removing the propeller shaft 1. 2. 3.
Place the machine in service position. Block the wheels so that the machine cannot start to roll and release all brakes. Make sure that the front or rear wheels are slightly raised off the ground before removing the propeller shaft's bolts.
Filling compressed air system If necessary, the compressed air system can be filled through the filler valve on the front part of the load unit frame by using compressed air from another machine. Releasing the parking brake When filling through the filler valve on the compressed air tank, the parking brake is released. The required minimum pressure is approx. 470 kPa (4.7 bar). The parking brake control must be in the operating position, that is, not applied. After recovering/towing The following safety measures should be taken before removing the towbar, heavy-gauge cable or chain after recovering/ towing: 1.
Park the machine on a level surface.
2.
Apply the parking brake.
3.
Block the wheels to prevent the machine from rolling.
Service Information Document Title: Steering description
Function Group: cylinder, 000
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Steering cylinder, description Showing Selected Profile Valid for serial numbers Model
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A25D Volvo There are two models of steering cylinders depending on serial number, see table below. Model A Machine
Place of manufacture, serial number EU
Brazil
A25D
–11949
–XXXXX
A30D
–10583
–70028
Model B Machine
Place of manufacture, serial number EU
Brazil
A25D
11950–
XXXXX–
A30D
10584–
70029–
Model A
Figure 1 Steering cylinder model A Pos.
Description
Pos.
Description
1
Cylinder barrel
10
Back-up ring
2
Piston rod
11
O–ring
3
Piston
12
Guide ring
4
Guide ring
13
Piston rod guide
5
Piston seal
14
Back-up ring
6
Back-up ring
15
Scraper
7
O–ring
16
Spring washer
8
Lock brace
17
Bolt
9
Piston rod seal
Figure 2 Steering cylinder, cut-away view, model A Pos.
Description
Pos.
Description
1
Cylinder barrel
10
Back-up ring
2
Piston rod
11
O–ring
3
Piston
12
Guide ring
4
Guide ring
13
Piston rod guide
5
Piston seal
14
Back-up ring
6
Back-up ring
15
Scraper
7
O–ring
16
Spring washer
8
Lock brace
17
Bolt
9
Piston rod seal
Model B
Figure 3 Model B Pos.
Pos.
1
Cylinder barrel
8
Back-up ring
2
Piston rod
9
O–ring
3
Scraper
10
O–ring
4
O–ring
11
Piston seal
5
Piston rod seal
12
Guide ring
6
Guide ring
13
Piston
7
Piston rod seal
14
Spiral spring pin
Figure 4 Steering cylinder, cut-away view, model B Pos.
Pos.
1
Cylinder barrel
8
Back-up ring
2
Piston rod
9
O–ring
3
Scraper
10
O–ring
4
O–ring
11
Piston seal
5
Piston rod seal
12
Guide ring
6
Guide ring
13
Piston
7
Piston rod seal
14
Spiral spring pin
Service Information Document Title: Troubleshooting strategy
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Troubleshooting strategy Showing Selected Profile Valid for serial numbers Model
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A25D Volvo Perform collection of basic data, see Collection of basic data Reading out error codes, see Error codes, showing. Any error codes? YES
NO
Note error codes. Solve/repair the problem. Activate the component/function in question. Reading out error codes. Problem solved? YES
NO
OK
Check parameters, see 35F9901 Parameter list. Parameters set correctly? NO
YES
Reprogram parameters. Problem solved? YES
NO
OK
Perform basic check, see Basic checks. Problem solved? YES
NO
OK
Troubleshoot symptoms. Problem solved? YES OK
NO Troubleshoot using other information. [1]
Relationships in troubleshooting strategy Example group 233 fuel feed. TROUBLESHOOTING, STRATEGY
collection of basic data Error code information
Error code information Reference to Reaction check from connectors, software cables and components
Parameter information
Software functions Function description
Parameter information
Error code read-out
Parameter settings
Basic checks, symptom groups
Basic checks
Check-measuring connectors, cables and components Wiring diagrams
VCADS Pro tests for component
Symptom groups
A basic check per main A list with groups per system: main system: Engine Engine Electrical Transmission system Transmission etc. Brake system - Steering and Start and stop problems hydraulics
PC-tests for all systems Example: Test no. 23017-8 Feed pressure, check
Wiring diagrams
Service information Group 233 fuel feed Content:
Individual symptom E.g., engine does not start General, possible causes, tips
Symptom group General, possible causes, tips
PC-test no. 23017-8 Specification Feed pressure, check s Function Check no. 23304-1 description Feed pressure, check - Removing/ (pressure gauge) installing Check/ adjusting - Evaluation of check
[1]Other information refers to e.g., diagrams, function descriptions and component troubleshooting.
Service Information Document Title: Troubleshooting, devices
Function Group: assistant 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Troubleshooting, assistant devices Showing Selected Profile Valid for serial numbers Model
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A25D Volvo To facilitate and make troubleshooting more effective, there are a number of tools available, such as the service manual, the service panel, the information panel and the VCADS Pro service tool. Service Manual The service manual contains service information for troubleshooting, such as Troubleshooting strategy; How to perform effective and systematic troubleshooting; see Troubleshooting strategy Collection of basic data; The questions that the operator ought to be asked to determine the nature of the malfunction and the conditions under which it occurred. See Collection of basic data. Error code information; Display all error codes; see Error codes, showing. Parameters; Display of machine and customer parameters; see 35F9901 Parameter list. Basic checks; Each main system, e.g. engine or electrical system, undergoes a basic check. The aim is to quickly and securely gain information on the condition of the subsystems of the main systems. See Basic checks. Service display unit The service panel can be used to read out information on the machine's systems. Such information includes pressures, temperatures and software. See Service display unit, general. Display unit The information display unit can be used to read out error codes and to show warning displays. VCADS Pro VCADS Pro is a PC-based tool designed for purposes such as facilitating troubleshooting. See VCADS Pro service tool, general.
Service Information Document Title: Troubleshooting, general
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
Troubleshooting, general Showing Selected Profile Valid for serial numbers Model
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A25D Volvo
WARNING Please pay attention to the safety instructions in the Operator's and Service Manuals concerned. General If a fault is suspected or established because symptoms have been experienced or error codes have been generated, it is important to determine the cause of the problem as quickly as possible. NOTE! In addition to error codes and symptoms, alarms from the central warning system can indicate a fault if they are not justified by the operating situation. Alarm conditions are described in the respective software function. Refer to the section 301 Software documentation. Strategy In order to make troubleshooting as efficient as possible, it should be performed following a number of predefined steps. See also Troubleshooting strategy. 1. 2. 3. 4. 5.
Collection of basic data – Collection of basic data Read error codes - see Error codes, showing Check parameters - see 35F9901 Parameter list Perform basic checks - Basic checks Troubleshot symptoms
In all troubleshooting it's important to follow the "course" that was chosen initially to be able to exclude malfunction causes part by part. At the same time, it's important to not "lock in" your thinking that, e.g., the problem must be in a certain component. Aids See Troubleshooting, assistant devices.
Service Information Document Title: VCADS Pro service general
Function Group: tool, 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
VCADS Pro service tool, general Showing Selected Profile Valid for serial numbers Model
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A25D Volvo
Figure 1 NOTE! Complete documentation for VCADS Pro is found in a separate introduction manual and in the user manual included in the software's help menu. VCADS Pro is a PC-based tool used for purposes such as downloading software, facilitating troubleshooting and making it more efficient. The name VCADS Pro is an abbreviation of Vehicle Computer Aided Diagnostics System Professional. VCADS Pro should be regarded as an advanced tool to be used together with the service manual and other special tools. VCADS Pro is connected to the J1587/J1708 information bus via the PC service socket. NOTE! Please send in your views on software and operations to vce.softwaresupport@volvo.com. Suggestions for new tests should include information on the purpose and application of the test. Identifying When the software is started, a dialogue box for entering machine type and model opens. This limits program display to the operations that apply to the selected model. Job card
In order for operations to be carried out, a job card must be created or an existing job card that is not completed must be opened. Job cards are used to store all work operations performed along with the results of the operations. The course of each operation can be played afterwards. Job cards can be stored locally in VCADS Pro or they can be exported and imported to make it possible to copy between different users/computers. This is useful, for example, when specialists are going to troubleshoot/diagnose machine malfunctions. All job cards are listed and accessible under the Job card menu. Operations All operations have an operation number based on Volvo's function register. The operations are sorted under each main system, such as "2 Engine". There are three different types of operations: Tests VCADS Pro, Test Calibrations VCADS Pro, Calibrating Programming VCADS Pro, Programming
Service Information Document Title: VCADS Pro tests
Function Group: 090
Information Type: Service Information
Date: 18-Feb-21
Profile: A25D Volvo
VCADS Pro tests Showing Selected Profile Valid for serial numbers Model
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A25D Volvo NOTE! These tests are currently available. New tests are developed continuously. For a current list of all tests, see VCADS Pro software. Group
Operation no., Test
Description/ Reference to service documentation
1. Service
17012-3 Error codes
The test makes it possible to read out and delete error codes. See Error codes, build-up.
Use component s
Tested Applies componen to ts machines A25D A30D A35D A40D
17034-3 Vehicle information, The test shows current vehicle test information, applying to hardware and software. See Software versions and ECUs/part number, checking. 2. Engine
21006-3 Cylinder compression, The test shows whether the SE2606 test compression of any cylinder differs SE2701 from that of the other cylinders. See Cylinder compression, PC test.
A25D A30D A35D A40D
23016-3 test
balancing, The test shows whether fuel injection MA2301– on any cylinder differs from that on MA2306 the other cylinders. See Cylinder balancing, PC test.
A25D[T1]
pressure, The test checks the feed pressure. See Feed pressure, PC test.
A25D A30D A35D A40D
Cylinder
23017-3 inspection
Feed
23712-3 manual
Injectors
shut
A30D[T2] A35D A40D
SE2301 SE2508 SE2701
off, The test supplements cylinder SE2606 balancing. In the test, one injector at a time can be turned off manually. See Injector shut-off, manual.
26351-3 Hydraulic cooling fan, The test controls the cooling fans' PWM2601 test speed control (independent of PWM2602
MA2301– MA2306
A25D[T3] A30D[T4] A35D A40D
MA5201
A25D A30D
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