Asphalt Compactors Volvo PT125C Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Asphalt Compactors Volvo PT125C, with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Asphalt Compactors Volvo PT125C 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.
Asphalt Compactors Volvo PT125C Service Repair Manual.pdf
Asphalt Compactors Volvo PT125C Parts Manual.pdf
PRODUCT DETAILS:
Total Pages: 827 + 212
File Format: PDF (Windows & Mac & Linux)
Language: English
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
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
03 - SPECIFICATIONS....4
Tightening torque; specifications....5
Thread locking compound; application_specifications....7
Hydraulic connections; tightening torques....9
07 - STANDARD TIME....16
Operation numbers for additional work....17
08 - TOOL....19
Infrared Thermometer....20
1 - STANDARD PARTS; SERVICE....22
16 - LUBRICANT; FUEL; OTHER FLUID....23
Fuel; lubricant and filling capacities....24
Recommended lubricants....25
Alternative fuels....27
17 - SERVICE....30
Tech Tool; operations ....33
Service and Maintenance Introduction....34
Arrival Inspection; according to Inspection Programme....35
Delivery Inspection; according to Inspection Programme....36
Maintenance of Stored Machines; according to Inspection Programme....37
Maintenance service; every 10 hours....38
Maintenance service; every 50 hours....39
Maintenance service; every 500 hours....40
Maintenance service; every 1000 hours....41
Maintenance service; every 1500 hours....42
Maintenance service; every 2000 hours....43
Maintenance service; every 3000 hours....44
Maintenance service; every 6000 hours....45
Service position ....46
Lubrication; every 50 hours....48
Engine belt tension; checking....50
Engine belt condition; checking....51
Crankcase ventilation separator element; replacing....52
Crankcase ventilation separator rubber hoses; checking....54
Valves; adjusting ....55
Engine oil level; checking....65
Engine oil and filter; changing....66
Water separator; checking....69
Fuel filter; replacing....70
Water separator filter; replacing....72
Fuel tank breather filter; replacing....74
Fuel hoses; checking....75
Fuel injectors; checking....76
Exhaust manifold; checking....77
Diesel particulate filter; checking and cleaning....78
DPF differential pressure pipes and hoses; checking....86
Turbocharger; checking....87
Engine air cleaner system integrity; checking....89
Engine air cleaner primary filter; cleaning....90
Engine air cleaner primary filter; replacing....93
Engine air cleaner secondary filter; replacing....96
Engine pre cleaner cyclone type; cleaning....99
Charge air pressure sensor; checking....101
Coolant level; checking....102
Coolant; changing....103
Coolant freezing point; checking....105
Cooling system integrity; checking....107
EGR system; checking....108
EGR cooler hose; checking....109
EGR cooler; checking....110
Battery system integrity; checking....111
Emergency stop switch; testing....112
Parking brake function; checking....113
Tyre wear and air pressure; checking....115
Wheel hub bearing; greasing....117
Centre wheel; adjusting....120
Wheel nuts torque; checking....121
Hydraulic oil level; checking....123
Hydraulic oil; changing....124
Hydraulic oil suction strainer; cleaning....127
Hydraulic oil filters; replacing....130
Water tank level; checking....132
Water tank; cleaning....134
Water pump filter; checking....136
Spray bars; cleaning....138
Towing a disabled machine....140
19 - GENERAL....146
Safety concerns everybody!....147
Service position....151
Some simple rules regarding tyre handling....153
Safety when handling the machine....155
A few simple safety rules....159
Before operating....163
Before service; read....167
General....171
Cleanliness....176
Electrical system....180
Checklist after a fire or heat exposure....184
Health hazards with paint; plastics and rubber....187
Safety when handling oil and fuel....191
Safety when working with batteries....194
Charging batteries....197
Environment....201
Environmental handling for the future....206
Decontamination....209
2 - ENGINE WITH MOUNTING AND EQUIPMENT....213
20 - GENERAL....214
Engine; description....215
Engine belt; removing....219
Engine belt; installing....220
Tech Tool; operations-5035....222
Component locations....223
E-ECU MID 128 pre-programmed; replacing....225
E-ECU MID 128 non-programmed; replacing....227
21 - ENGINE....229
Engine; removing....230
Engine; installing....237
Engine; specifications....244
Engine rotation speed sensor (crank shaft); replacing....246
Engine rotation speed sensor (camshaft); replacing....248
Engine; tightening torques....250
Valve cover; removing....254
Valve cover; installing....258
Valve system; specifications....263
Valves; adjusting....264
Engine mounts; replacing....275
22 - LUBRICATING SYSTEM....285
Lubrication system; component locations....286
Lubricating system; description....287
Lubrication system; specifications....291
Lubrication system; tightening torques_{040-41}....292
Lubrication system; tightening torques_{040-23}....293
Lubrication oil pressure; checking with pressure gauge....294
23 - FUEL SYSTEM....296
Fuel system; description-3903....297
Fuel system; description....303
Fuel system; specifications....309
Fuel system; tightening torques_{037-40}....310
Fuel system; tightening torques_{037-22}....311
Fuel system; bleeding....312
Fuel pump unit; replacing ....313
Fuel tank; removing....320
Fuel tank; installing....331
Injectors; replacing....341
Overflow pipe; inspecting....344
Fuel rail; replacing....347
Fuel pump unit; replacing....350
25 - INLET & EXHAUST SYSTEM....357
Inlet and exhaust system; tightening torques_{030-27}....358
Inlet and exhaust system; tightening torques_{030-09}....359
Exhaust Aftertreatment System; description....361
Regeneration process; description....365
Inlet throttle; replacing....367
DOC (Diesel oxidation catalyst); replacing....373
Turbocharger; removing....380
Turbocharger; installing....383
Wastegate; checking....386
Air cleaner; removing....388
Air cleaner; installing....390
26 - COOLING SYSTEM....392
Cooling system; description....393
Cooling system; tightening torques....397
Cooling system; specification....399
Cooling package; removing....400
Cooling package; installing....407
Coolant pump; replacing....414
Thermostat; replacing....420
29 - MISCELLANEOUS....424
Exhaust Gas Recirculation (EGR); description....425
EGR cooler; replacing....429
EGR cooler pressure; testing....432
EGR valve; replacing....435
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....437
30 - GENERAL....438
Tech Tool; operations....441
Software parameters; description....442
General fault diagnosis information....447
Troubleshooting strategy....448
Collection of basic data....450
SAE error codes; translation to error messages; general....452
Conditions when checking....455
Lead and connector checks....457
Troubleshooting tools....461
Special tools for troubleshooting....462
Tech Tool Service Tool....463
AL3201; description and measuring....466
FX1052; description and measuring....468
FX1053; description and measuring....470
FX1054; description and measuring....471
HE2501; description and measuring....472
MA2301-MA2304; description and measuring....474
MA2310; description and measuring....476
MA4202; description and measuring....477
MA4212; description and measuring....479
MA4407; description and measuring....481
MO2506; description and measuring....482
MO3301; description and measuring....483
MO5401; description and measuring....485
Power supply E-ECU; description and measuring....487
RE01; description and measuring....490
RE03; description and measuring....493
RE08; description and measuring....495
RE14; description and measuring....497
RE2501; description and measuring....499
SA3601; description and measuring....501
SAE J1939_CAN1 Control link; description and measuring....502
SAE J1939_CAN2 Control link; description and measuring....504
SE2206; description and measuring....507
SE2302; description and measuring....508
SE2303; description and measuring....509
SE2306; description and measuring....511
SE2309; description and measuring....512
SE2502; description and measuring....513
SE2507; description and measuring....514
SE2508; description and measuring....516
SE2510; description and measuring....517
SE2519; description and measuring....519
SE2521; description and measuring....521
SE2522; description and measuring....523
SE2603; description and measuring....525
SE2606; description and measuring....526
SE2709; description and measuring....528
SE2710; description and measuring....529
SE5501; description and measuring....530
SE8501; description and measuring....531
SE8502; description and measuring....532
SE9105; description and measuring....534
SE9428; description and measuring....535
SE9809; description and measuring....536
SW5501; description and measuring....537
Multimeter 8889 0074....539
Test pins 999 0008....540
Adapter cable 999 0020....541
Extension cable 999 0062....542
Adapter cable 999 3893....543
Multi-pin breaker box 999 8699....544
Template 8889 0019....545
Harness 8889 0016....546
Adapter cable 999 0014....547
Adapter cable 999 0216....548
Component fault diagnosis; description....549
Test methods; description....552
33 - STARTING SYSTEM....555
Starting system; description....556
36 - OTHER ELECTRICAL EQUIPMENT....559
V-ECU MID 187 pre-programmed; replacing....560
V-ECU MID 187 non-programmed; replacing....562
37 - CABLE; FUSE; RELAY....564
Component list; fuses....565
Component list; Miscellaneous....567
Component list; motors....568
Component list; relays....569
Component list; sensors....571
Component list; Solenoid valves....572
Component list; Switches....573
E-ECU; I_O list....578
I-ECU; I_O list....583
V-ECU; I_O list....584
Wiring diagram index....587
Wiring diagram 1....588
Wiring diagram 2....591
Wiring diagram 3....594
Wiring diagram 4....597
Wiring diagram 5....600
Wiring diagram 6....603
Wiring diagram 7....606
Wiring diagram 8....609
Wiring diagram 9....612
Wiring diagram 10....615
Wiring diagram 11....618
Wiring diagram 12....621
Wiring diagram 13....624
Wiring diagram 14....627
Wiring diagram 15....630
Wiring diagram 16....633
Wiring diagram 17....636
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....639
Fuel level sender; replacing....640
4 - POWER TRANSMISSION....664
42 - TRANSMISSION; HYDRAULIC CONTROL....665
Propulsion control cable; replacing....666
Propulsion control lever; replacing....669
44 - HYDROSTATIC DRIVE....672
Propulsion system; tightening torques....673
Propulsion pump; specifications....676
Propulsion motor; specifications....677
Brake_shunt valve function; description....678
Propulsion system; description....681
Propulsion motor; removing....685
Propulsion motor; installing....687
Propulsion pump; removing....689
Propulsion pump; installing....692
Propulsion pump high pressure relief valve; replacing....694
Charge pressure relief valve; replacing....698
Charge pressure relief valve; adjusting....702
5 - BRAKE....706
55 - PARKING BRAKE....707
Parking brake; function description....708
6 - STEERING....712
60 - GENERAL....713
Steering system; specifications....714
Steering system; tightening torques....715
Steering system; description....717
62 - STEERING AXLE....720
Steering bearing; replacing....721
Spindle; removing....727
Spindle; installing....729
64 - STEERING....731
Steering pump; removing....732
Steering pump; installing....734
Steering valve; replacing....736
Steering cylinder; removing....740
Steering cylinder; installing....742
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....744
71 - FRAME....745
Frame; tightening torques....746
72 - SUSPENSION....747
Centre mount; replacing_{11-50}....748
Centre mount; replacing_{11-33}....750
Centre mount; replacing_{11-15}....752
75 - AXLE SUSPENSION....760
Suspension; removing....761
Suspension; installing....765
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....768
Wheels; tightening torques....769
Tyres; specifications....771
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....772
81 - CAB; NAKED; CANOPY....773
Operator's platform; tightening torques....774
86 - PROTECTIVE EQUIPMENT....776
FOPS (Falling object protection structure); removing....777
FOPS (Falling object protection structure); installing....780
ROPS (Roll Over Protection); removing....783
ROPS (Roll Over Protection); installing....785
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....787
90 - GENERAL....788
Hydraulic diagram; component locations....789
Hydraulic diagram 1....793
Hydraulic pressure; testing....797
Hydraulic system; tightening torques....799
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....800
Hydraulic oil tank; removing....801
Hydraulic oil tank; installing....809
98 - FUNCTION FOR ROAD CONSTRUCTION....817
Water spray system; description....818
Water pump; removing....820
Water pump; installing....822
Water tank; removing....824
Water tank; installing....826
0 - Foreword.....2
2 - ENGINE WITH MOUNTING AND EQUIPMENT.....3
21 - ENGINE.....4
Engine 12818054.....5
Repair kits for engine 17263037-[2720].....7
Repair kits for engine; upper gaskets 17263037.....8
Repair kits for engine; lower gaskets 17263037.....10
Cylinder head 17263037.....12
Valve cover 17263037.....14
Crankshaft and related parts 17263037.....15
Piston kit 17263037.....17
Valve mechanism 17263037.....18
Rocker arm shaft 17263037.....20
Camshaft 17263037.....22
Repair kits for engine 17263037.....24
Crankshaft ; pistons and connecting rods 17263037.....26
Crankshaft _ flywheel 17263037.....28
Oil sump 17263037.....30
Oil dipstick 17263037.....32
Oil drain 12767477; S_N -327064.....33
Oil drain 12767477; S_N 327065-.....34
Engine mounting.....35
22 - LUBRICATING SYSTEM.....37
Front cover 17263037.....38
Sensor 12767477.....40
Oil cooler with hoses 17263037.....41
23 - FUEL SYSTEM.....43
Fuel filter 17263037.....44
Fuel tank.....45
Fuel Lines.....46
Injection pump 17263037.....48
Common Rail 17263037.....50
Fuel pipes-injector 17263037.....52
25 - INLET & EXHAUST SYSTEM.....54
Inlet manifold 17263037.....55
Air Cleaner Inlet Pipe 17263037.....56
Exhaust manifold 17263037.....57
Inlet system 17263037-[1900].....58
Inlet system 17263037.....59
Exhaust manifold.....60
Diesel Particulate Filter 17263037-[1809].....61
Diesel Particulate Filter 17263037-[1749].....63
Diesel Particulate Filter 17263037-[1729].....65
Diesel Particulate Filter 17263037.....66
Turbo charger 17263037.....67
Oil pipe 17263037.....69
Breather Pipe 17263037.....71
Fuel filter _ water seperator 17263037.....73
Air cleaner installation.....75
Air filter.....77
26 - COOLING SYSTEM.....78
Radiator installation.....79
Expansion tank with fitting parts.....81
Cooling system 17263037.....83
Waterpump; assembly 17263037.....84
Cooling fan mounting 17263037.....85
Fan Assembly 12767477.....86
28 - IGNITION AND CONTROL SYSTEM.....87
Engine ECU 17263037.....88
Ecu; assembly 12767477.....89
Engine harness 17263037.....90
Fastenings for Cable Harness 17263037.....91
Sensor 17263037.....93
29 - MISCELLANEOUS.....95
Egr system 17263037.....96
Egr system; valve 17263037.....98
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS.....99
31 - BATTERY.....100
Battery with assembling details.....101
32 - ALTERNATOR; CHARGE REGULATOR.....102
Alternator with assembling details 17263037.....103
Alternator 17263037.....104
33 - STARTING SYSTEM.....106
Starter motor with assembling details 17263037.....107
Starter 17263037.....108
Ignition Starter Switch.....110
Lighting; front 12799579.....111
Work lights 12796766.....112
Hazard Flasher_Turn Signal Installation 12796768.....113
36 - OTHER ELECTRICAL EQUIPMENT.....114
Horn.....115
Back-up warning unit.....116
Rotating beacon 12820237.....117
Side console-[0721].....119
Switch 12796768.....121
37 - CABLE; FUSE; RELAY.....122
Battery cable and main switch.....123
Wiring harness; chassis-[0619].....125
Wiring harness; chassis.....127
Cable harness; steering console-[0543].....129
Cable harness; steering console.....130
Cable harness; work lights 12799579-[0508].....131
Cable harness; work lights 12799579.....132
Cable harness; rotating beacon 12820237.....134
Cable harness; side console-[0417].....135
Cable harness; side console.....136
Electrical distribution box.....138
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM.....140
Buzzer.....141
Speedometer Installation 12820774.....142
Temperature Sensor 12820940.....143
Display panel.....144
4 - POWER TRANSMISSION.....145
44 - HYDROSTATIC DRIVE.....146
Drive Motor Installation.....147
Wheel Drive Motor.....149
Pump; Mounting 12767477.....151
5 - BRAKE.....152
52 - HYDRAULIC BRAKE SYSTEM.....153
Hydraulic system; brake line.....154
6 - STEERING.....156
62 - STEERING AXLE.....157
Steering Bolster And Spindle Installation.....158
Double-ended Spindle and Hub Assembly.....160
64 - STEERING.....162
Pedestal Assembly.....163
Steering system.....165
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT.....167
71 - FRAME.....168
Heat shield 12822977.....169
Coverplates.....171
75 - AXLE SUSPENSION.....173
Suspension System Installation.....174
Arm Assembly.....176
Spindle Assembly.....177
77 - WHEELS; TRACKS; TYRE; HUB; DRUM.....179
Wheel and tire 59283176.....180
Wheel and tire 13373071.....181
Nylon Scraper Installation 58936162.....182
Steel Scraper Installation 59038059.....184
Cocoa Mat Installation.....186
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE.....187
82 - ENGINE HOOD; MUDGUARD; FOOT STEP.....188
Engine hood 12769100.....189
Engine hood 12819137.....191
85 - CAB INTERIOR; UPHOLSTERY.....193
Operator seat with fitting parts.....194
Operator's seat.....195
88 - INTERIOR EQUIPMENT.....197
Side console.....198
Manual Case Installation 12795667.....200
89 - MISCELLANEOUS.....201
Sign plates and decals.....202
Sign plates and decals 12795960.....204
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS.....206
98 - FUNCTION FOR ROAD CONSTRUCTION.....207
Water System Installation.....208
99 - MISCELLANEOUS.....211
Vandalism kit 12820696.....212
Asphalt Compactors Volvo PT125, PT125C Service Repair Manual
