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    197365-Volvo A30C

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    Alfie b. bagsao

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    © All Rights Reserved
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    VOLVO Service Information Consist Ein Document Tite: Function Group: Information Type: Date: Description 000 Service Information 06.03.2013 Profile Description Articulated Hauler A30C consists of two main sections, the tractor unit and the load unit, The two units are joined by the frame steering joint which allows movement about a vertical axis for steering. The hitch joint allows the two units to move and twist in relation to each other along a horizontal axis, The tractor unit consists of a six-cylinder diesel engine, transmission and dropbox, as well as a drive axle, The cab is rubber mounted on the frame, Springs are mounted between the frame and the drive axle, ‘The load unit consists of frame, elevation load body, front and rear driving bogie axles which are linked by a bogie suspension. ‘The A20C has constant 4-wheel drive with the possibility to engage 6-wheel drive. Ithas a longitudinal differential lack in the dropbox and differential locks on all drive axles, VOLVO Service Information Document Tite Function Group Information Type: Date Dimensions 030 Service information 06.03.2013 Profle: Dimensions Figure 2 Rs Figure 4 A30C Dimensions with tires 23.5 R-25 dimension mn inches Total length A 10200 4016 Total length, tractor unit [As 4862 i914 Total length, load unit A: 5856 2306 Lead body length, standard |B S167 2034 body Total height at exhaust pppe_|C 3410 1343 Height to cab roof c. 3260 1283 (Overhang, front D 2770 108.1 Overhang.fronteyelets —_[D: 2730 1075 Distance, front axle -[E 1210 476 articulation joint Distance, drive axles F 4173 1643, Distance, bogie axles G 1670 657, Overhiang, rear H 1587 a5 (Overhang, frame r 239) 173 Loading height 3 2834 1116 Height to load body K 2180 358 Clear tipping height tL 594 234) Total height, raised load|M 6494 2557 body Outer tuming radius IN 8074 3179 Inner turning radius Ni 4021 1583 (Outer width, load body o 2932 1184 Inner width, load body P 2720 107.1 Width, bottom of load body _[Q 2286 90.0 Minimum clearance, load ]R 530 209) unit Bottom of load body - side |S 1464 576 cf load body Bottom of load bady - rear of |T 310 319) load body ‘Maximum height, body front |U 3305 30.1 plate ‘Track with load unit Vv 2216 87.2, Total width, load unit Ww 2820 0 Minimum dearance, tractor |X 485, 191, unit Minimum clearance, hitch | Xs 670. 264 x 1893 745 Xe 3802 1497 Track width, tractor unit | 2216 872, Total width, tractorunit |Z 2820 10 ‘Angle of approach a 2 23° Tipping angle a 70° 70° Maximum steering angle [as 45° 45° VOLVO Service Information Document Title: Function Group Information Type: Date: Product Identification|030 Service Information 06.03.2013 Number and Serial Number Locations (Type plates) Profile Product Identification Number and Serial Number Locations (Type plates) ‘The illustration below indicates where the different type plates are located on the machine. The type plate designations and Product identification Numbers (PIN) must always be correctly quoted when ordering parts and in any telephone inquiries lor correspondence concerning service matters. 3 4 [Fexonioacr 90017 00000 7 Figure 1 Serial Product Identification Plates and Number Locations Drive axle serial numbers are located on respective avle housing, 2 Dropbox serial number is stamped into the rear right-hand side of the box. 3. Cab type, type approval and serial number are located on the let inside the cab. 4. Product Identification Number, PIN for complete machine (includes type, product, serial number and CE-approval) ‘The type plate is located at the rear let side of the tractor unit. ‘The serial number of the machine is also stamped into the right side of the tractor unit frame, ‘Transmission type designation and serial number are located on the left-hand side of the transmission, Engine type designation, part and serial number is stamped into the left-hand side of the engine block now VOLVO Service Information Document Title Function Group Information Type: Date Specifications 030 Service information 06.03.2013 Profle: Specifications Figure 1 ‘Type and Product Numbers, Articulated Hauler A30C ‘TD 103 KBE - "8188140" PT 1663 - "12037930! AH 631 -"23727" FL650 E - "22504" AW 63 J - 23728" PReene AH 63 K - "23728 VOLVO Service Information Document Title: Function Group: linformation Type Date. [Volvo standard tightening| 030 Service Information 06.03.2013 torques Profile: Volvo standard tightening torques ‘The tightening torques in the following tables apply to bolts and nuts with tensile strengths as noted below. The tables should be used as a general instruction for tightening torques of bolts and nuts which have no specified torque values indicated Torque values should be increased by 10 % for flanged bolts type USFS. Bolts and nuts should be cleaned and lubricated with ol, Tensile strength 8.8Metric coarse and fine threads Thread Nm kpm Ftlb M6 10 10 74 MB 24 24 18 Mio 48 43 35 Miz 35 35 e Mua 40 140 103 Mis 220 220) 160 M20 430 #30) 320 M24 740 740 550 ‘Tensile strength 10.9Metric coarse and fine threads Thread Nm kpm Ftlb Me 12 12 8 MB 30 30 2 Mio 60 60 44 M2 105 105 78 Mia 375) 175 230 Mis 275 275 204) M20 540 540 [400 Maa 05 205 584 ‘Tensile strength 8.8UNC threads, coarse Thread Nm kpm Ftlb aa 3 08 66 spe 18 18 B 3/8" 33 33, 24 As 34 54 40 ue 80 80 59 se 120 120 9 5/8" 370 170 FE a 300) 300 220 7 435, 485 360 r 725 725 530 VOLVO Service Information Consist Ein Document Tite: Function Group: information Type Date: Time Guide 070 Service Information 06.03.2013 Profile Time Guide Regarding: A30C 16 Lubricants, fuels and other liquids Opne. Time @) Operation 16206 1 Engine, changing ol end filter 16232 3 Brake system, changing ollfuid and filter 16234 1 Hydraulic oll tank changing oll and flier excl cleaning tank 16236 1s Hydraulic oll tank changing oll and fiter incl cleaning tank 16238 1s Transmission, changing oll and fiter and cleaning suction strainer 16250 1 Drop box, changing cil/deaning suction strainer 16260 3 ‘Ales, chaning cll 6x6 27 General 17001 075 (Washing, extemal cleaning 37101 1 [Arrival inspection. according to programme 37102 1.25 Delivery inspection, according to programme 37202 7 ‘Waranty inspection 100 hours, according to service programme 17204 10 Warrenty inspection 1000 hours, according to service programme 17302 0.25 Maintenance service, daly 17304 075 Maintenance service, every 50 hours 37307 4 Maintenance service, every 250 hours 27310 a4 Maintenance service, every 500 hours 17312 7 Maintenance service, every 1000 hours 17314 16 Maintenance service, every 2000 hours 21 Engine, general 21002 2 [Compression test, engine at operating temperature 21070 85 Engine, removing 2071 a5 Engine removed, general overhaul 072 i Engine iting 21073 58 Engine and transmission, removing Z074 7 Engine and transmission, mounting 2412 075 Valves, adjusting 2496 15 Valve cap, changing 23 Fuel system, general 23201 0s Fuel system, bleeding 23304 075 Feed pump, checking feed pressure 23601 05 ling speed, checking and adjusting 23602 05 Stall speed, checking 23603 025 dling speed, checking 73604 025) Tow idling speed, checking and adjusting 23630 15 Injection timing, checking and adjusting 23631 Injection timing adjuster, checking 23702 Injectors, replacing all 25 Inlet and exhaust systems 25570 0s Turbo charger, removing 25571 15 Turbo charger. replacing 25572 1 Turbo charger, fitting 25601 os Air cleaner, cleaning fiter element 25602 025 ‘Air cleaner, checking prssure drop indicator 25603 0S [Air leaner, primary filter replacing 25604 05s Air cleaner, secondary filer replacing 26 Cooling system 26102 025 Coolant, checking anti-freeze resistance 26104 1S Coolant, changing 26108 25 Radiator, replacing 26110 1 Radiator, adjusting 26172 os Coolant fiter, changing 26271 2 Coolant pump removed, reconditioning 26301, 075 Fan motor, removing 26202 1 Fan motor, changing piston rings 26303 1 Fan motor, fiting 726304 1 Fan motor, checking working pressure 26305 025 Fan motor, adjusting working pressure 26306 1 Fan hydraulically driven, removing pump, 26307 1 Fan hydraulically driven, fitting pump 26309 075 Fan hydraulically driven, replacing cil return filter 26310 05 Fan hydraulically driven, checking standby pressure 26312 05 Fan belt and/or altemator belt, replacing 26313 05 Fan belt andor elternatorbelt, checking and adjusting tension 26322 05 Fan belt and/or alternator, compressor bel replacing all belts 26502 15 Intercooler, change 26812 25 Enging heater, fing new 31 Battery and mounting parts 31101 OS Batteries, checking charging capacity 31102 15 Batteries, replacing 32 Alternator and charge regulator 32102 05 Alternator, replacing incl function check (00 measuring instrument) 3274 15 (Charging test _in_machine (with measuring instrament) 33 Starting system, general 33199 125 [Starter motor removed replacing arbon brsh kit 35 Lighting 35202 05 Headlights, adjusting against well or screen 35208 05 Headlemp reflector end/or glass replacing one inel adjusting 35224 05 Head lamp es5y, replacing one incl scjusting 35316 05 Reer lamp, replecing one 35318 05 Rear lamp, replacing gass or bulb 35601 1 Rotating beacon fitting new 35656 05 ‘Work lighting replacing one head lamp easy 35657 05 (Work ighting replacing one insert 36 Other electrical equipment, general 36102 05 Flasher unit replacing relay 36110 05 Flasher switch, replacing 36117 05 Flasher lamp, replacing glass or bulb 36202 05 Horn replacing 36203 05 Reverse alarm, replacing 36216 05 Honn sutch replacing 36302 15 [Windscreen wiper front, replacing motor 36303 05 Windscreen wiper replacing switch 36204 os Windscreen flusher pump, replacing 36404 05 Switch replacing 36408 05 Brake light siteh, replacing 36720 05 ECU, replacing 42 Transmission, general 2149 075 Transmission, changing turbine speed sender unit 42150 075 Transmisson, resistance measuring of] cablehamess ast 05 Transmission, resistance measuring of] solenoides 2154 a ‘Seal for rear output shaft, replacing 42157 05 Retarder valve, replacing of seal 42159 05 Transmission retarder valve, adjusting air pressure 42160 05 Transmission, resistans testing control system azie1 1 Induction sensor for output shaft, changing 42165 5 [Control system, replacing 42168 55 Transmission, removing (upwards) 2169 55 Transmission, fitting (from above) 42170 7 Transmission, removing 42172 8 Transmission, fitting 42178 2 Transmission, remove and fitting from @ non mounted engine 42179 0.25 Transmission, replacing breather fiter ‘43 Gearbox, mechanical 43402 2 Dropbox, replacing seal for front otput shaft 43404 2 Dropbox, replacing seal for rear output shaft 43415 4 Dropbox, replacing seal for input shaft 43416 1 Dropbox, oil pump, replacing 43461 075 Differentiel lock longitudinal, adjusting /engagement 43473 a5 Dropbox fitting 43074 a Dropbox, removing 43702 175 ‘Checking of main, torque converter and lubricating oil pressure 45 Propeller shaft incl. bearings and mounting 45104 15 Propeller shaft, rear, replacing 45105 Propellershaft for rear boggle axel, replacing 45107 075 Propeller shaft, in frame joint, replacing 45110 075 Propeller shaft, front, replacing 45113 15 Propeller shaft, removed reconeiiioning asia 35 Propeller shaft between transmission and dropbox, replacing 46 Drive axles, general 4643 4 Hub, replacing seal 46516 05 Dog clutch 636, checking and adjusting 46805 0s Differential lock rear, adjusting engagement 51 Wheel brake, all 1001 45 Brake linings, checking wear 1002 0.25 Brake disc for service brake, checking 1101 os Brake pads for service brake, checking 102 45 Brake disc, replacing one sii04 3 Brake pads, replacing on both sides of| al su05 1s Brake pads, replacing (one wheel, front ale) suas 2 Brake caliper. replacing one S118 1 Brake callper removed, reconditioning 51201 05 Brake linings, checking wear rear ale 1202 45 Brake asc, replacing one 1204 3 Brake pads, replacing on both sides of| ale 51205 18 Brake pads replacing (one wheel fst bogie axe) 524s 25 Brake clipe. replacing one 51281 1 Brake caliper, removed, reconditioning 52 Hydraulic brake system 52037 1 Brake system, bleeding 55 Parking brake inclcontrol system 55002 os Parking brake, adjusting 55008 25 Parking brake, replacing brake dise 55009 0s Spring brake cylinder, replacing sso10 1 Spring brake cylinder removed reconditioning 55012 1 Parking brake (if, replacng brake caliper 55012 075 Parking brake caliper (ei), removed raconcitioning Seon 1 Parking brake, replacing brake peds 55102 1 Parking brake, (removed) reconcitioning of brake caliper 56 Air operated brake 56104 L Compressor, replacing 56122 0.25 Pressure regulator, adjusting 56310 1 Relay vale (oad unit), reconditioning inl removing and fitting 56372 1 Foot brake valve (pneumatic) removed reconditioning 64 Steering 64226 3 ‘Steering gear, replacing 64310 35 ‘Steering linkage. checking and adjusting 64501 0s ‘Steering linkage, checking and adjusting 64503 0s ‘Steering system, checking working pressure 64506 5 Steering cylinder replacing asa 1 ‘Steering cylinder, replacing link bearings 64560 [Steering gjinder repacking in machine 64580 ‘Steering valve neutral position and valve spool end float, checking 4581 3 Steering valve removed, reconditioning 64582 3 Steering valve, replacing 64504 0s Damping ojinder, checking spring force 64585 Damping cylinder, changing seal 64793 ‘Auxiliary steering, replacing hydraulic pump 64785 05 [Auxiliary steering, adjusting working end stand: by pressure 6 68527 3 Front A-stay loading unit, replacing link bearing 65528 3 Rear A-stay losding unit replacing link bearing 71 Frame, general 71120 3 load unit frame, checking measurements 72 Springs 72701 5 [Spring element front, replacing all 74 Frame joint, general 74105 0s Frame joint checking clearance 74106 Frame joint, measuring and adjusting learence 74136 Frame joint, replacing bearings 7140 Frame joint, changing hitch 74207 10 Frame joint replacing hitch 74238 a5 ‘Articulated joint, checking clearence 74240 9 ‘Steering joint. replacing bearings 7a20a 2 Aticulated joint, replacing bushing 7A2N6 1s Frame joint, changing metalic bearing (machine separates) 75 Axle suspension, general 75410 3 Replacing lnk bearing (rubber bearing), front ade 7542 rl Front bogie ade cross stay, adjusting 75431 1 Rear bogie axle cross stay, adjusting 75611 Bogie member, replacing rubber| bearing (one side) 75612 1 Torsion bar rubber bushing (bearing), changing (ront) 75614 1 Torsion bar rubber bushing (bearing), changing, ear 75615 Torsion bar checking and adjusting 73624 Bogie beam, changing rubber spring, one side (front) 75626 3 Bogie beam, changing rubber spring, one side (reat) 76 Shock absorber, anti-roll bar, level, side contr. 76101 2 ‘Shock absorber front, replacing all 77 Wheel, Tyre, Hub, Crawler/Track 77101 05 (Wheel, removing and fitting 84 Outside trim parts, Glass, Sealing, Mouldings 84302 ‘Windscreen, replacing e432 15 Rear window, replacing a3 ‘Sicle window, replacing 84348 Door window, replacing 85 Upholstery 38202 1 [ir spring for operator's seat, changing 87 Air Conditioning unit 87304 1s Radiator, replacing 87306 15 Fan motor, replacing 87308 1 Heat control vahe, replacing 87402 15 Refrigerant, draining 7403 05. [Cooling unit, performance test 87404 7 ‘Cooling unit fitting new incl filing 87405 2 Refigerant, filing excl vacuum pumping 87406 4 ‘Compressor, replacing inc! draining and filling 91 Working hydraulic and servo system 91284 125 Tipping cylinder, replacing 91303 05 [Ol pump, checking and adjusting standey pressure 91304 05 [Oil pump, checking end adjusting working pressure 91308 2 (Oil pump. ground dependent, changing 95 Load carrier 95101 05 Tipping contro, adjusting 95102 2 Tipping valve, changing wire 95103 05 Dump —bedy postion indicator, adjusting 95108 5 Dumping (hoist) cylinder, changing 95106 35 Dumping hoist) cflinder removed, raconcitioning 95110 Tipping valve, replacing 95140 Dump body joint. changing tipping bearing 95142 15 Dump body, adjusting against frame VOLVO Service Information Document Title: Function Group Information Type: Date: Drawings of E-tools that|030 Service Information 06.03.2013 can be made in your own ]workshop Profile Drawings of E-tools that can be made in your own workshop Measurements on all drawings are in mm unless otherwise indicated. £1057 C, Transmission lifting device 2250106 ROR/ PIE - toast gr 40 ee Figure 1 £1057 C, Transmission lifting device Bolt, 2 pcs, MLOxI6 (part nr 940148) Ball bearing, 3 pes SKF 6305 110238 Wesher, 4 pes, 25/35 mm t=2mm, @98/138in t=0.08in) Sheet metal plate, 2 pcs. 35x40mm t=3mm (L381 57in t=0.19in) Bolt 4 pes, MBX (pert nr 955294) Washer, 4 pes 85/16 mm (33-0.63in) (part nr 955894) Sheet metal plate Sheet metl plate Bolt, 2 pes, MSx25 (part nr 955249) Nut 2 pes, MS (part nr 955780) Alternative postion for support leg Support legs, adjustable length, $40-680 mn (21.26-26.77in) E 1643, Transmission transport/lifting device (door method) Figure 2 E 1643 Lifting device Max: load 500 kg (1103 Ibs) A Novae Must be marked with “Maximum load 500 kg (1103 lbs)" after it has been manufactured Lifting device, 1 pe. see welding drawing E 1643-1 Wheel, 1 pc. see welding drawing E 1643-2 Locking pin, pe see welding drawing E 1643-3 Cotter pin, 1 pc. d=O8 Bolt, 1 pc MES 20x110 fb Lock nut, 1 pe. M20 f2b Washer, 4 pcs, BRB 21x36 x3fzb Welding and detail drawing on page 0:33 and 0:3. £1643-1, welding drawing ‘Measurements on all drawings are in mm unless otherwise indicated. Figure 3 1643-1 1 Square pipe 2pcs. material 2132 120x60x6 L=840 2 Squere pipe 2 pes material 2132 1120x6036 L=1394 3 Squere pipe Ape. material 2132 120x606 L=200 4 Sheet metal 2 pes. material 2132 101754150 5 Sheet metal pe material 2132 10475180 6 Flat bar 2 pes. material 2132 100x6 L=140 7 Sheet metal 2 pes. ‘material 1312 3xS4xL14 8 Flat bar pe. material 2132 ‘50x10 L=400 9 Round bar 2 pes. material 2172 19 1=480 1643.2, detail drawing Figure 4 Round bar, 1 pe. 1643-3, detail drawing Figure 5 2Chain link, 1 pe, alt round bar O10, L=257 3 Round bar, 1 pc, 020 h10 L=90 All material: 2172 E1644 Transmission lifting device (door method) SSS sss SSSSSESS”SSSEaSSSSSSS Pa scat tee ses ae ke Figure 6 E 1644 Transmission lifting device (door method) 1 ipc Pipe material 2172 or 2124 50/40 L=aa0 2 2p Sheet metal 2132 6x80x200 3 Ips Sheet metal 2132 10,68x250 Maximum load 500 kg (1103 Ibs) Welding classification WB Cutting classification SK2 £ 1645, Body support Figure7 E 1645, Body support 1 Body support, Ipe. See weld and detail drawing on pages 0:38 and 0:39 | 2 3 Plug, 1 pe Locking bolt, 1 pc. See detail raving on page 040 See detail drawing on page 0:40 1645-1, Welding drawing Figure 8 1645-1 Materials list, see detail drawing on page 0:39 £ 1645-2, Detail drawing Figure 9 1645.2 NOTE All measurements are in mm unless otherwise indicated, 1 [Sheet metal plate L pe material 2132 2079990 2 Round bar Lpe material 2172 12 317 3 Square pipe pe material 2132 80,8006 L=464 4 Square pipe Lpe material 2132 0x80n5 L=390 5 Flat bar pe material 2132 0x10 L=132 6 Sheet metal plate L pe material 2132 xeay15 7 Sheet metal plate Lpe material 2132 x76415 8 Flat bar 1 pe material 2132 0xd0 L=187 3 Flat ber 3 pes. material 2132 50x6 L=23 10 Flat ber L pe material 2132 100x8 L=200 n Rubber cushion Part nr 11049133-9 L=90 B Flat ber pe material 2132 ‘50x6 L=103 4 [Welding nut MoM 16 is Flat bar 1 pe material 2132 4008 1=80 £ 1645-3, detail drawing = | | | ! 4 1 i | I I te! 40 H10 Figure 10 1645.3, A Plug 8. Locking bolt L_Pipe, 1 pc. material 2172 045/28, L=200 2 Round bar, 2 pcs material 2172 © 12, h=10, L=80 3. Bolt, 1 pc MES 16x80 fully threaded 4, Pipe dowel FRPEx60 E 1664, Differential lock adjusting tool 300 : al Pt a ea Gf A sove80 = Figure 11 E 1664, Differential lock adjusting tool ABRBO 30x 8x2 To be welded in the hole NOTE All measurements are in mm unless otherwise stated £1666, Hub lifting device " 4 io 1666-4 1666-5 1666-2 1666-7 £1666-8 1666-6 1666-3 M1280 venewaen 1666-1, -2, -3, detail drawing 2 ee cae-2 Figure 13 ‘A Square pipe 60x60x4 B. Square pipe 50xS0x4 NutM12.@% D. NutMa2 1666-4, detail drawing am |. a 28 | us 3 na Figure 14 Ball bearing, 4 pes. 6004 RS 2 Snapring (grooved ring), 4 pes. Sqa 20 3. Bolt, 4 pcs, M10x20 4. Washer, 4 pos. BRB 10,5222 NOTE! All measurements are in mm unless otherwise indicated, 1666-5, -6, detail drawing i Figure 15 NOTE! All measurements are in mm unless otherwise indicated A. Square pipe 60x60x4 B Square pipe S0xéox4 NutMiz D.-NutM12@9 E 1666-7, detail drawing 2s os Figure 16 NOTE! All measurements are in mm unless otherwise indicated, A. Square pipe S0x50x4 B NutM12 (2) Square pipe 60x60x4 £ 1666-8, composite drawing EH) Figure 17 NOTE! All measurements are in mm unless otherwise indicated, 1666-8 Locking lever Straight coupling (link) with spring ISO 168-1, Linch CBH bolt, steel 8x40 Cotter pin 2125 Bolt M12x30 ov eene E 1666-8, detail drawings Figure 18 NOTE! All measurements are in min unless otherwise indicated, Free from weld Nut M12 Square pipe 60x60x4 Square pipe 60x40%4 Screw MFX M6xI6 (4x) Plastic material mmone> £ 1667, Hub lifting device eset 2 eat i" 090 Ogu [re Siig i, RZ) SE On 35 s 00 | 5. ) nf +2 I 2h. 200 | : — 3 ah CD) a Toxase t E Pe qi x. O— i G 3 ; Q 8 Veet ete [se eee eee Joa eevee + B a 2» osu OK aerosa VOLVO Service Information Document Tite Funetion Group Information Type: Date Towing 100 Service information 06.03.2013 Profle: Towing Preparations to be made before recovering or towing If possible when recovering or towing, the engine should be running to ensure that braking and and steering functions are operational Before beginning any preparations for towing or recovery, the parking brake must be applied and the wheels blocked to prevent the machine from rolling. Exceptional care must be taken when towing to avoid accidents resulting in personal injury or, in worst cases, fatality. Recovering = Use a towbar connected to the front or rear eyes on the machine when towing to a suitable location or passable road. Filling compressed air system Compressed air can be filled when necessary through a filer valve on the front part of the load unit frame, by using air from another machine. The valve is used to release the parking brake when the compressed air system is empty and the compressor is non-operational. Figure 1 1 Filler valve Releasing the parking brake Only the parking brake is released when filing compressed air through the right valve, see fig. Required minimum pressure approx 400kPa (4 bar) (58 psi). No pressure reaches the service brakes. Releasing the parking brake and pressurizing the service brakes Filling can also be done through the left valve but requires @ minimum pressure of 650 kPa (6.5 ba) (94.25 psi). The parking brake is then releaced and the service brake Grcut will also be pressurized, ‘The brakes on the machine are only operational as long as there Is sufficient pressure remaining in the system, VOLVO Service Information Document Title: Function Group Information Type: Date: towing of machine, |100 Service Information 06.03.2013 general Profile: Towing of machine, general = Use a towbar or heavy wire attached to the front eyes of the machine if the machine has to be towed to a workshop after recovery, ~If the brakes are not operational, always use a towbar, The towing vehicle must be at least as heavy as the vehicle in tow and have sufficient engine and braking capacities to pull and brake both vehicles on uphill and downhill inclines. Always tow only the shortest necessary distance, Maximum speed under all circumstances is 10 km/h (6.2 mph). Itis not possible to start the engine by towing. Filling of compressed air, see previous page, Figure 1 Alnput propeller shaft Towing If the engine can not be started: ‘Towing should be restricted to emergencies and only the shortest necessary distance since braking and steering functions will be limited. Towing should only be done by trained personnel and, if possible, transport the machine ona trailer. Case 2 (with engine running) The gear selector should be in neutral, and the parking brake released. The machine can be towed up to 10 km (6 miles) ‘without making any special preparations, Case 2 (without the engine running) ‘The input propeller shaft must be disconnected from the dropbox since the transmission will not get any lubrication when the engine is non-operational. Removing the propeller shafts Park the vehicle in the service position = Block all the wheels sa that the machine is prevented from rolling and release all brakes. ~Make sure that the front or rear wheels are slightly above ground before the propeller shaft bolts are removed. After recovering/towing The following safety procedures must performed before removing towbar or wire: Park the machine on @ level surface, Apply the parking brake. ~Block the wheels to prevent the machine from rolling, VOLVO Service Information Document Tite: Function Group: Information Type: Date Cleanliness, brake and] 170 Service Information 06.03.2013 hydraulic systems Profile Cleanliness, brake and hydraulic systems ‘The greatest pcesible cleanliness must be observed when werking on these systems. Wipe off all pipe and hose connections before they are disconnected, remove all paint flakes etc. Plug all pipes, hoses, cylinders, etc. immediately after disconnecting or removal. Never re-connect an unplugged hydraulic hose without first flushing it out with hydraulic ol VOLVO Service Information Document ite Function Group Information Type: Date Electric welding 170 Service information 06.03.2013 Profle: Electric wel ‘The electric current must be turned off using the battery disconnect switch before any welding is done on the machine or attached implements, Figure 1 Connection cable for electronic control unit ‘The connection cables of the electronic control unit for the transmission must be disconnected. The ignition key must be position 0 to make sure that the cable is powerless (zero volts) when disconnecting or re-connecting. Connect the welding unit (ground clamp) as close to the welding point as possible. VOLVO Service Information Document Title: Function Group Information Type: Date: A few simple rules for|191 Service Information 06.03.2013 batteries Profile: A few simple rules for batteries ~ Batteries give off explosive gases. Never smoke in the vicinity of batteries Figure 1 ~ Battery acid is corrosive and causes burns, avoid getting it on bare skin — When disconnecting a battery, always begin by removing the ground lead. Always ettach the ground lead last when Installing the battery to reduce the risk of sparks that can cause fire, = Never tilt a battery in any direction as the battery electrolyte may leak out. —When charging batteries, follow the instructions on the next page, = When starting using a booster battery, follow instructions on the next page, = Never connect a discharged battery in series with a fully charged battery. The current surge may cause the battery to explode. ~ Avoid contacting the battery terminals with metal objects (e. tools, rings, watches, etc), Personal injury and fire may result Always replace terminal protective covers (caps). — Batteries contain substances dangerous to personal health and the environment. Discarded batteries must be disposed of according to existing local and national regulations concerning battery disposal Starting with booster batteries ‘The following instructions must be followed when starting with booster batteries Check that the booster batteries or any other power source has the same voltage as the standlard batteries, ‘The current surge that reults when discharged batteries are connected to fully charged batteries may cause a battery ‘explosion, resulting in personal injuries. Proceed as follows: Connect the (+) terminal on the booster battery to the (4) terminal on the starter motor, then connect the other jump-start lead from the (-) terminal on the fully charged battery to the frame on the machine, ie. the starter motor attaching bolt or the frame member near the starter motor, ‘When the engine has started, first remove the jump-start lead between the frame and the booster battery () terminal. Then remove the jump-start lead between the (4) terminals. Do not break the circuit between the standard batteries and the machine! Figure 2 Charging of batteries During rapid charging of batteries, always remove the cell covers (caps). During charging, an explosive mixture of ‘oxygen and hydrogen is formed. A short-circuit, open flame or spark near the battery can cause a powerful explosion. Always turn off the charging current before disconnecting the charging clamps. Ventilate well, especially if the battery is being charged in a confined area, ‘The battery electrolyte contains corrosive sulphuric acid. Any spilled electrolyte on the skin should be removed immediately. Wash with soap and rinse with plenty of water. If electrolyte should splash into eyes or any other sensitive part of the body, rinse immediately with plenty of water and contact a physician immediately. Figure 3 VOLVO Service Information Construction Eginneat Document Tite: Function Group: Information Type: Date: A few simple rules of{191 Service Information 06.03.2013 service work Profile A few simple rules of service work Figure 1 = No work must be dene on the machine until service personnel appointed to do the work have sufficient knowledge about the machine to do the job properly = Machines operating within contaminated areas (polluted environment or unsanitary areas) must be equipped in a special ‘way. Special safety regulations also apply when servicing such machines. ~ Service work not done correctly is dangerous. Make sure service personnel have sufficient knowledge, correct information, the proper toals and equipment to service the machine in a correct manner. Repair or replace any braken or damaged tools and equipment. ~ Read all plates and instructions on the machine and in the Operator's Manual before doing any service work on the machine, Each one contains important information with regards to safety and handling of the machine, Check that all anti-slip surfaces are in place. If not, replace or fasten. —When using high pressure to wash the machine, do not alm the waterjet directly at anti-slip surfaces that are glued on. ~Make sure that stepping surfaces, service areas, handles and anti-slip surfaces are clean and free from ol, fuel, dirt or ice ‘and that they are changed if they are damaged or missing, ‘Never step or walk on machine surfaces not intended for this purpose. = Never wear loose clothing or jewellery that can get caught when working on the machine and cause personal injury, ~ Always use a hard hat, safety glasses. gloves, workboots/shoes and other protective items when the working situation demands it Figure 2 ~The steering frame joint must be locked when doing service work close to the joint Figure 3 Figure 5 ~ Always stop the engine during service unless plates or instructions in this manual state otherwise, = When changing oil in the engine, hydraulic system or transmission, beware that the oil may be hot and can cause severe burns Beware of hot fluids and hot components that can cause severe burns if you have to do service work before the machine has cooled down. = Take measures to avoid unnecessary spillage when draining oils or fuel. When it is impossible to drain directly into a container, use @ pump or connect hose for safe handling of the fluid Oils freely discharged into the environment cause damage and are a fire hazard. Used cils and other fluids must be taken care of by dispacal firm where knowledge to handle these types of waste exists. — Use lifting equipment with the lifting capacity at least equalling the weight of the part or component you are lifting. Figure 6 All lifting devices such as straps, slings, ratchet blocks, et. must comply to the national standards for lifting devices, Volvo Construction Equipment will not accept any responsibilty if any other lifting devices, tools or working methods than those escribed in this service manual are used. ~If a garage jack must be used, make sure that the surface is level and is sufficiently firm to support the load to be lifted. — Prevent the machine from rolling by applying the parking breke and by placing suitable blocking by the wheels that are not lifted ~ Always use a garage jack with sufficient lifting capacity. When lifting, place the jack under the axle or on the inside of the ‘wheel that is to be removed. ‘Make sure that the jack is correctly positioned and at the correct angle to the lifting point on the machine. — Always place supperts under the machine in an appropriate way in the uplifted position ‘The hydraulic jack must always be relieved of the load by support stands under the lifted axle before the wheel is removed. ~ Stop the engine before opening or removing engine hood, radiator casing, and any other covers. Make sure that tools or ther items that can cause damage are not forgotten in the machine, Figure7 Make sure that all hoods, covers and doors are in place and closed before starting the engine and operating the machine —When checking for leaks, use paper or a stiff board - not your hand, Release the system pressure before doing any work on the brake or hydraulic systems ~ All pressurized reservoirs and tanks must be opened gradually and carefully. When the engine has been stopped there Is still an accumulated pressure in the systems, I @ system is opened before having been released of any remaining pressure, oil under high pressure will rush out. ‘Any checking and re-tourging of leaking couplings and connections must be done with the systems void of any accumulated pressure, — Hydraulic system: must be relieved of influence from all external loads and forces affecting the cystem, = Brake system: the pressure in fully hydraulic brake systems with accumulators is released by stopping the engine and fully depressing the service brake pedll several times (20-40 times). Discarded accumulators must be punctured before they ate scrapped, otherwise the risk of explosion remains, Never adjust pressure valve to @ higher pressure than recommended by the manufacturer — Park the machine on @ level and firm surface and block the wheels. Make sure that all brakes are released and that the front and rear wheels are off the ground before removing any of the propeller shaft attaching belts. = Install communications radios, mobile telephone units, etc, to specifications of the manufacturer in order to prevent and eliminate interference with electronic systems and components controlling the functions of the machine, = Do not stand behind the machine when the engine is running, ~ After completing service work, close and secure all protective covers and the engine hood. VOLVO Service Information Document Title: Function Group Information Type: Date: ple rules when] 191. Service Information 06.03.2013 inflating tires A few simple rules when inflating tires ~The tre pressure should be checked with the load body empty. Make sure you stand off to the side of the tire when inflating a tire mounted on a split rim. Wheels of this type may explode causing personal injury or even death. Use a self-attaching air-chuck with a hose long enough to allow tire inflation from outside the tire trajectory path. Always use an inflation cage, safety cables or chains to secure @ wheel not mounted on a vehicle when inflating the tire —Donot cut or weld the rim of an inflated tire. —Never combine a tre with a rim unless itis recommended, = Never use wheel or rim parts of different sizes in combinations and never use damaged or incorrect parts ~ Be careful when using re-conditioned wheel parts. Incorrect welding, heating or soldering of the parts may cause it to weaken and result in future failure, ~Let the air out ofthe tire before removing foreign objects from the tread, ~ Take care when working with bead breakers and hydraulic jacks, and stay out of the trajectory path when removing foreign objects from the tread, If a beadbreaker disengages, it releases with 2 force great enough to cause vely severe injuries or even death, —Make sure that the locking groove is free from dirt, rust, debris, et. before installing the ring VOLVO Service Information Construction Eginneat Document Tite: Function Group: Information Type: Date: Before operating 11 Service Information 06.03.2013 Profile: Before operating 50368 Figure 1 ~The rules given in the Operator's Manual apply to the operation of the machine, Read what is to be done before sitting in the operator's seat and driving the machine, ‘A few important rules are listed below — Defects or failures that affect safety must be repaired as soon as possible. ~ Read all type plates and instructions that are on the machine and in the Operator's Manual before operating or servicing the machine, Each instruction contains important information with regards to safety, handling and servicing of the machine. — Always use a hard hat, protective glasses, gloves, protective workboots or shoes when the working situation requires it for your continued safety. Ensure that there is adequate ventilation system capacity before starting the engine indoors. ~ Always sit in the operator’s seat when starting the engine, Use 2 hip-type seatbelt during all operation of the machine, Figure 2 —Make @ control light test before starting the engine by turning the ignition key to position 1, see Operator's Manual Perform all recommended safety checks ‘The machine must be parked in the correct Service Position when the checks are done. For Service Position, see page 5. not implemented: INTKREF ~~ = Never operate the machine while under the influence of alcohol, medicines or other drugs. = Do not operate the machine for long periods without ventilation or with a fully closed cab without having the fan on (to avoid a lack of ai A ladder may be needed when servicing the machine and when changing bulbs or replacing lights. ~ Always face the machine when entering or leaving and use theprovided steps and handles. Use two hands and one foot or cone hand and two feet. Do not jump! Figure 3 Step only on the prepared non-slip surfaces and use provide handles and railings Do not overload the machine. Overloading will impair safety! VOLVO Service Information Document Title: Function Group Information Type: Date: Dangers in connection with] 191. Service Information 06.03.2013 polymer materials Profile: Dangers in connection with polymer materials Work on painted surfaces ~ When welding and cutting, all paint must be removed at least 10 em (4 inches) around the welding/cutting point. Heated paint will give off harmful vapours and gases ~ All paint disintegrates when heated and forms a large number of different compounds which may be iritating and may constitute a severe health hazard after long and frequent exposure, = In addition to the detrimental health effects, the weld will be of inferior quality and strength which may cause a future failure Never weld directly on @ painted surface, ‘The following safety instructions must be followed: Remove the paint around the working area by sand blasting. Use appropriate breathing protection, safety mask, ete If the work area can not be sand blasted, remove the paint using approved solvents. When working with solvents, use air extractor fan (suction), breathing protection and protective gloves. — High-speed grinding machines and grinding discs also heat the paint and must only be used if there is an air extractor fan (suction) on the grinding machine, Always use breathing protection, Rubber and plastics Polymer materials can form compounds dangerous both to personal health and environment when heated. ‘Therefore, never weld close to parts made of rubber or plastics. The following safety instructions must be followed: —Do not weld or cut near polymer materials (plastics or rubber) without frst protecting them from the heat, Never burn polymers when discarding them. Be careful when handling machines that have been exposed to intense heat or have been burnt. — Always use protective glasses/goggles, gloves and approved breathing protection. Figure 1 Fluor rubber Certain seals designed to withstand high operating temperatures (ie. in engines, brakes, transmissions, axles, hydraulic motors and pumps) can be made af fluor rubber which will farm hydrogen flucride and hydrofluoric acid when heated to high temperatures, This acid is highly acidic and corrosive and can not be removed by rinsing or waching it off the skin, Hydrofluoric acid also causes very severe burns which take a very long time to heal, AAs a rule, injured tissue must be removed surgically. It can take several hours after contact with the acid before any symptoms become apparent and thus there is no immediate warning of contact. The acid may remain on machine parts for several years after a fire If swelling, redness or a burnings sensation appear and there is suspicion of contact with heated fluor rubber, contact a physician immediately. If a machine or component has been burned or exposed to to intense heat, it must be handled by specially trained personnel. Thick protective rubber gloves and tight-fitting safety goggles must be ‘worn when handling machines or any components after fires. ‘The area around a heated part which is suspected of being made of fluor rubber must be decontaminated ly thorough and ample washing with lime water ( 2 solution or suspension of calcium hydroxide, that is, slaked lime in water). Upon completion of the work, protective gloves are washed in the lime water and discarded in an appropriate manner. Never burn discarded painted parts, rubber or plastic detalls. This type of waste must be disposed of by a licensed disposal company, Checklist The following protective measures must under all circumstances be taken when handling machines or components damaged by intense heat or fire; ~As.a precaution, always handle all seals (O-rings, axle seals and all other oll seals) as if they were made of fluor rubber. Never touch burned components with bare hands when there is risk of contact with melted polymer materials. First was thoroughly with lots of lime water (a solution or suspension of calcium hydroxide, slaked! lime in water). Use thick protective rubber gloves and tight-fitting safety goggles. =If contact with fluor rubber is suspected, treat the affected skin area with Hydroflucric Acid Burn Jelly, or the equivalent. Contact physician immediately. Symptoms from contact with the fluor rubber may not appear for several hours. ~ Discard protective gloves, rags. ete. and other materials that have been in contact with or are suspected of having been in contact with the fluor rubber. Make sure to dispose ofthis waste in an appropriate manner, VOLVO Service Information Document Title: Function Group Information Type: Date: Fire prevention measures |191. Service Information 06.03.2013 Profile: Fire prevention measures — There is always a risk offre. Learn what types of fire extinguishers to use, where they are kept and how how to use them, wrt «| \ Figure 1 D At the slightest sign of fire, and ifthe situation allows it, take the following pre- cautionary steps to ensure you own safety: Drive away the machine from the danger area. Lower the load body onto the frame. ‘Stop the engine using the stop control and turn the ignition key to the "0" position, Leave the cab. Disconnect the rain current using the battery disconnect switch. Start extinguishing the fire and call the fire department when necessary 000000 — Smoking or open flames are not allowed anywhere near the machine during filling of fuel or when the fuel system has been opened to contact with the air Figure 2 ~ Diesel fuel is flammable and should not be used as a cleaning solution, use an approved solvent instead, Some solvents may cause skin rashes and are usually lammable/fire hazards. Avoid inhslation the vapours from solvents, ~ Starting gases may be flammable, Keep any such items in cool and well ventilated storage areas, Remember that starting (gases and the like must not be used together with preheating of the induction air. = Keep your work area clean, Cleanliness is a decisive factor in the safe and trouble-free operation of the machine cystems. il and water make floors and steps slippery and are also dangerous when using electric power tools or working on electrical systems, Oily and greasy clothing also create a serious fire hazard, — Make daily checks to ensure that the machine and equipment, underbody plates, etc, are free from dirt, grease and oil The risk of fire is reduced and iti easier to notice problems with machine parts or parts that are loose. Take extra care if a high-pressure wash is used for cleaning since the jet may cause damage to electrical components and insulation of electric cables, even at moderate temperatures end pressures, Protect electrical components and cables in an appropriate manner, Keep the machine extra clean when working ina fie hazardous areas, such as saw mills, garbage dumps, etc The machine should be equipped with devices that reduce accumulation of combustible materials ie. radiator screen, high capacity cyclone precleaner, exhaust system and silencer guards ete. ~ Fire fighting equipment installed on the machine must be maintained in working order. Such equipment should be regarded as a complement to the operator's own actions in case of fire - not as replacements to the cperator’s own efforts to fight the fire ~ Check to see if electric cables have been damaged by chafing or friction and make sure that they can not be damaged in that way. Pay particular attention to unprotected circuits which are red and marked R (B+). See cables betneen; 1 Batteries 2 Battery - Starter motor 3. Altemator - Starter motor 4, Lead to preheating coll, inlet manifold In cases where unprotected circuits have been disconnected, itis important to check that they are connected end clamped in such a way thet they are not exposed to frictional wear. Unprotected circuits must not rest on fuel or cil lines. ~All electric leads must be connected across a fuse and cables must be routed, connected and clamped to avoid frictonal ‘wear when optional or extra equipment is fitted on the machine. ~ Check that there is no frictional damage or chafing of fuel, hydraulic and brake hoses and lines, = Welding and grinding wark an the machine must anly be done in a clean areas free from flammable materials. Take extre care when welding or arinding is necessary close to flammable materials, See also “Dangers in connection with polymer materials” A fire extinguisher must be kept close by and ready for use during such work. = Components such as batteries, plastics and other materials harmful to the environment must not simply be thrown out Make sure that this type of waste is taken care of in an appropriate environmentally sound manner VOLVO Service Information Document Tite: Function Group: Information Type: Date Preparations before towing |191 Service Information 06.03.2013 Profile: Preparations before tor 9 See the Service Manual, Section 1- Service and Maintenance, or the Operator's Manual, chapter Operating Instructions. VOLVO Service Information Document Title: Function Group Information Type: Date: Refrigerant for air 191. Service Information 06.03.2013 conditioning Profile: Refrigerant for air conditioning Reter also to section Safety and Section & Personal competence and accreditation(=authorization). Service workshops must be accredited to handle refrigerants. Atleast one person in a supervisory position at an accredited workshop must possess certified knowledge. Accreditation is applied for at the appropriate national authority, according to existing lav Refrigerant R134a R13da is hazardous to personal health. ‘When there is probability of direct contact Use tight-fitting safety glasses or protective goggles. During repeated contact Use protective rubber gloves. ‘The refrigerant in liquid form can cause: Frost-bite. In high concentrations the gas cen have: ‘Anaesthetic effects. In low concentrations the gas can have: Some effects, particularly on the nervous system. Ifunprotected parts of the body come into conact with R134a, act as follows: Splash in eyes: Rinse immediately with plenty of water, preferably running. Contact physician immediately. Skin contact In case of frost-bite, lush with lukewarm water for a long time. Contact physician immediately. Inhalation: Move persons out of the danger area into fresh air. If someone is seriously affected, contact a physician immediately. VOLVO Service Information Document Title: Function Group Information Type: Date: Refrigerant for air 191. Service Information 06.03.2013 conditioning units Profile: Refrigerant for air conditioning units General ‘Anew refngerant 1348 for ar-concitioning units has been introduced instead of R12. See alco Section 8 ‘The type plate shows which type of refrigerant that is used. There is also a type plate near the recelver drier when refrigerant 14a is used, The R134a has been developed to have less of an environmental impact and as en altemative to the earlier refagecant R12, The Rl4a does not have any depletion potential that wil affect the ozone layer of the atmosphere - the 12 does, However, the R134a does add to the greenhouse effect and must never be released into the open air. 34a is moderately dangerous to personal health Follow local rules and regulations for handling of refrigerant. Personnel competence and accreditation (authorization) Service workshops must be accredited to handle refrigerant. ‘There must be at least one person in a supervisory position with accreditation (authorization) at an accredited workshop. ‘Accreditation is applied for at the national authorities, according to national laws. Equipment for service Pressure reservoirs/tanks, filing unit, vacuum pump and hoses, etc, which are used for servicing @ system filled with one type of refrigerant must never come into contact with another type of refrigerant. Even very small quantities of R12 for instance has a great decomposing effect on RL34a, This may lead to the destruction of components in the refrigeration unit. Personal protective equipment Weer the following when there isa risk of liquid contact: Tight-fitting goggles/safety glasses, protective gloves and protect bare skin (risk of frost-bite). Do not wear contact lenses. Figure 1 Health risks In liquid form the refrigerant can cause frostbite. ‘The gas can to some extent at low concentrations especially affect the nervous system. ‘The gas can at high concentrations have @ narcotic effect. ‘The explosion risk makes it necessary to avoid exposure of the gas cylinders to temperatures no higher than + 40°C (204-°F). Any increase in temperature will also increase the risk of explosion. First Aid in case of accidents, Inhalation ‘Move personnel away from danger area if there is suspicion of refrigerant gas vapours escaping into the air. Low concentrations of R134a can have some effect on the nervous system, high concentrations can have a narcotic effect. If someone is seriously affected by the inhalation of vapours, contact a physician immediately. Skin contact: In cases of frost-bite, rinse the affected area with lukewarm water for some time. If a large amount of refrigerant should come into contact with the skin, the injured area should be warmed with lukewarm water and warm clothing. Contact a physician if the symptoms persist. Slash into eyes: Rerigerant R134a ‘mediately rinse with plenty of running water. Contact physician if symptoms persist. — Use great care when working with all refrigerants, The AC system contains pressurized refrigerant. Refrigerant must not be purposely released into the environment, If work js to be done on the AC system, the refrigerant must frst be collected in a special refrigerant pressure reservoir/tank for re- Use alternatively destruction. ~The AC system is pressurized and refrigerant may unintentionally leek. Never loosen or diccannect hases or filing valve on the compressor. When leakage is suspected, the system must not be "topped up". Contact an authorized Volvo Construction Equipment workshop for proper service. — Equipment specially designed for handling of refrigerantmmust be used when doing work such as charging (filing), or

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