Volvo Tracked Pavers ABG7820, ABG7820B Service Repair Manual
Complete repair service manual with Eletrical Wiring Diagrams for Volvo Tracked Pavers ABG7820, ABG7820B, with all the technical information to maintain, diagnose, and repair like professional mechanics.
Volvo Tracked Pavers ABG7820, ABG7820B 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.
Volvo Tracked Pavers ABG7820B Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,232
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description...4
03 - SPECIFICATIONS...5
Volvo standard tightening torques...6
Component locations...9
Instruments and operating controls; specifications_{35-32}...11
Instruments and operating controls; specifications_{35-10}...12
Instruments and operating controls; specifications_{34-49}...13
Instruments and operating controls; specifications_{34-27}...14
Conversion tables...16
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...20
Machine; transporting...21
07 - STANDARD TIME...24
Operation numbers for additional work...25
08 - TOOL...27
E-7006...28
E-7008...30
E-7009...32
E-7014...34
1 - STANDARD PARTS; SERVICE...37
16 - LUBRICANT; FUEL; OTHER FLUID...38
Lubricants; service capacities and intervals_{25-48}...39
Lubricants; service capacities and intervals_{25-20}...40
Lubricants; service capacities and intervals_{24-56}...43
Lubricants; service capacities and intervals_{24-30}...46
Lubricants; service capacities and intervals_{24-08}...47
Coolant...48
Alternative fuels...49
17 - SERVICE...52
Arrival Inspection; according to Inspection Programme...57
Delivery Inspection; according to Inspection Programme...58
Maintenance of Stored Machines; according to Inspection Programme...59
Warranty inspection 100 hours_{21-15}...60
Warranty inspection 100 hours_{20-53}...61
Warranty inspection 100 hours_{20-25}...62
Warranty inspection 100 hours_{20-04}...63
Maintenance service; as required_{19-30}...64
Maintenance service; as required_{19-09}...65
Maintenance service; as required_{18-41}...67
Maintenance service; as required_{18-20}...68
Maintenance service; every 10 hours_{17-46}...70
Maintenance service; every 10 hours_{17-24}...72
Maintenance service; every 50 hours...73
Maintenance service; every 100 hours...74
Maintenance service; every 500 hours_{16-08}...76
Maintenance service; every 500 hours_{15-47}...77
Maintenance service; every 1000 hours_{15-13}...79
Maintenance service; every 1000 hours_{14-52}...80
Maintenance service; every 2000 hours_{14-18}...82
Maintenance service; every 2000 hours_{13-57}...83
Maintenance service; every 2000 hours_{13-35}...84
Maintenance service; every 3000 hours_{13-01}...85
Maintenance service; every 3000 hours_{12-39}...86
Maintenance service; every 4000 hours_{12-06}...87
Maintenance service; every 4000 hours_{11-44}...88
Service positions; overview...89
Service position 1_10-52...91
Service position 2_10-12...94
Service position 3_09-34...96
Cleaning...100
Transmission oil level; checking...103
Coolant; level; check...104
Coolant level; checking...106
Primary fuel filter; changing_{06-50}...107
Fuel filter; replacing_{06-25}...109
Fine fuel filter...110
Coolant; draining...112
Coolant; filling...114
Hydraulic oil level; checking...115
Hydraulic oil return filter; replacing_{04-05}...116
Hydraulic oil return filter; replacing_{03-40}...118
Hydraulic tank ventilation filter; changing...119
Engine oil level; checking...121
Engine oil and filter; changing...123
Engine oil; draining_{01-39}...125
Engine oil; changing_{01-14}...127
Engine oil filter; replacing...128
Engine oil; filling...129
Track motor gearbox; changing oil...130
Auger drive chain; adjusting_{59-12}...133
Auger drive chain tension; adjusting_{58-48}...135
Air cleaner; primary filter replacing...137
Air cleaner; secondary filter replacing...139
Fuel line; water separator; check and drain...140
Fuel filter; replacing...142
Fuel system; bleeding...144
Transmission; changing oil...146
Oil return filter; replacing...147
Hydraulic oil; changing ...150
Auger drive chains; checking and adjusting...152
Fuel tank; draining...154
Conveyor drive chain; checking...156
Hydraulic oil; changing...157
Hydraulic oil tank; draining...158
Hydraulic oil tank; filling...159
Engine mounts; checking...161
Conveyor drive chain; adjusting_{50-55}...162
Conveyor drive chain tension; adjusting_{50-30}...164
Conveyor tension; checking ...166
Fan belt and_or alternator belt; checking and adjusting tension...168
Generator belt tension; adjusting...171
Fuel pump belt tension; adjusting...173
Distributor gear; changing oil...175
Fuel; filling...178
Sound insulation...180
Filter insert...181
Switch cabinet_{45-55}...183
Switch cabinet_{45-30}...184
Alternator belt; checking_{44-11}...186
Alternator belt; checking_{43-46}...188
Alternator belt; adjusting...189
Alternator belt; removing_{42-44}...190
Alternator belt; removing_{42-20}...192
Alternator belt; installing_{41-43}...194
Alternator belt; installing_{41-18}...196
Conveyor tension; checking...199
Conveyor belt covers_{40-16}...200
Conveyor belt covers_{39-51}...201
Auger bearings; greasing...202
Chain channel; draining...204
Auger helicals; changing...205
Oil level...207
Road scrapers...209
Towing arms_{36-28}...210
Towing arms_{36-03}...211
All-weather roof_{35-30}...212
All-weather roof_{35-05}...213
Conveyor drive chain...214
Generator; cleaning...215
Engine air cleaner primary filter; cleaning and replacing...217
Engine air cleaner secondary filter; changing_{33-09}...219
Engine air cleaner secondary filter; changing_{32-45}...220
Water separator_{32-11}...221
Water separator_{31-46}...222
Conveyor drive shaft; checking...223
Batteries...224
Hopper...226
Central lubrication...227
Filling lubricant...229
Central lubrication system; bleeding...231
Over load relief valve...233
Lubrication channel...235
Fuel system; air bleeding...237
Belt tension; adjusting...239
Pump distributor gear...240
Ventilation filter...241
Conveyor...242
Front cross beam...244
Bearing protector_{24-43}...245
Bearing protector_{24-19}...246
Bearing protector_{23-54}...247
Travel gear...248
Hydraulic system_{22-45}...249
Hydraulic system_{22-23}...250
Coolant; changing...251
Coolant anti-freeze resistance; checking...254
Fuel pump; changing belt...256
All-weather roof pump oil; changing...259
Water separator; cleaning...261
Belt; replacing_{19-13}...263
Belt; replacing_{18-48}...265
Charge air cooler; draining...268
Valves; adjusting_17-43...270
Conveyor chain; adjusting...286
Lubrication...288
Washing; external cleaning...289
Bolted joints; check tightening torque...290
Towing; measures...291
19 - GENERAL...295
CE-marking; EMC-directive...296
Starting with booster batteries...298
Safety during work on machines...300
Safety when working on hydraulic systems...303
Environmentally safe handling...305
Environmentally hazardous fluids...307
Service position 1...309
Service position 2...312
Service position 3...314
2 - ENGINE WITH MOUNTING AND EQUIPMENT...318
21 - ENGINE...319
Engine; specifications...320
Valves; adjusting...321
25 - INLET & EXHAUST SYSTEM...337
Diesel particulate filter system; description...338
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...341
30 - GENERAL...342
Auxiliary control panel; specifications...348
Switch cabinet; gas screed heating; specifications...349
Instruments and controls; overview_{59-45}...351
Instruments and controls; overview_{59-06}...355
Instruments and controls; overview_{57-43}...363
Instruments and controls; overview_{57-18}...365
Parameter codes...367
Software parameters; description_{55-46}...369
Software parameters; description_{55-01}...392
Software parameters; description_{54-16}...415
Menu tree...438
Control panel; parameter setting...449
Machine; Calibration_{52-10}...451
Machine; Calibration_{51-46}...454
Machine; Calibration_{51-21}...457
Control unit; software update...458
Control panel; software update...463
Conversion table SAE J1587- SAE J1939...467
EPM II Service Tool...478
Error codes; build-up...481
Error code information; description_{46-57}...483
Error code information; description_{46-35}...484
1 STOP on external control panel [left _ right] has been actuated!...534
2 CAN communication defective...535
3 Control no. [x] reports Fault!...536
4 Caution System operating with the auxiliary control panel!...538
5 Errors when reading the parameters...539
6 Error when writing the parameters...540
7 Retransmit parameters in ECU [x]!...541
10 Message database too large - automatically saved...542
12 Calibration Error...543
13 Error when reading the retain values...544
15 Error in CAN connection to control panel...545
16 Error when reading the machine no...546
20 Fault in steering potentiometer...547
21 Fault in speed potentiometer...548
22 Service due [x]h ago...549
23 Service performed at [x]h...550
24 Service performed at [x]h (service technician)...551
25 Service definition unavailable...552
4001 Error on sensor travel drive [left _ right]!...553
4011 Fault steering sensor...555
5001 Diesel engine; coolant level too low [x] °C!...556
5002 Diesel engine; oil pressure too low [x] bar...558
5003 Diesel engine; coolant temperature too high [x] °C!...560
5004 Diesel engine; charging air temperature too high [x] °C!...562
5005 Diesel engine; error on speed sensor [x] 1_min!...564
5006 Diesel engine; faulty charge air pressure sensor [x] bar!...566
5007 Diesel engine; faulty oil pressure sensor [x] bar!...568
5008 Diesel engine; faulty coolant temperature sensor [x] °C!...570
5009 Diesel engine; faulty charge air temperature sensor [x] °C!...572
5010 Fuel low pressure Beyond specified range...574
5011 Fuel low pressure sensor Cable break or short circuit...576
5012 Air filter differential pressure sensor Voltage outside the target range...578
5013 Battery Voltage below specified range...580
5014 Battery Above specified range...581
5015 Fuel temperature Above specified range...582
5016 Fuel temperature sensor Cable break or short circuit...583
5017 Oil temperature Above the target range...585
5018 Oil temperature sensor Cable break or short circuit...587
5019 Engine stop request ignored by operator...589
5020 Diesel fuel on reserve level!...590
5022 EMS Main Relay Short Circuit or Emergency STOP (Pin [x])...591
5023 EMS Main Control Relay Short Circuit...592
5024 Main relay Short circuit or emergency STOP...593
5025 Main Control Relay Short Circuit 24 Volt...594
5040 EMS connection interrupted...595
5050 EMS; CAN Bus Controller...596
5051 EMS; CAN Interface...597
5052 EMS; Bus error...598
5053 EMS; write EEPROM...599
5054 EMS; Programme Test...600
5055 EMS; RAM Test...601
5056 EMS; internal electric power supply...602
5057 EMS; internal temperature...603
5058 EMS; Atmospheric pressure...604
5059 EMS; Read EEPROM...605
5060 EMS; Batch overflow...606
5061 EMS; Internal error...607
5070 Unknown EMS error!...608
5080 Error EMS; FMI and SPN...609
5090 Check motor identification...610
5100 Generator is not charging [x] V!...611
5200 Error; heating isolation!...613
5220 Error; temperature sensor [x] n°C!...615
6001 Error return filter 1...617
6002 Error return filter 2...618
6003 Hydraulic oil temperature too high [x] °C!...619
6004 Error; hydraulic oil temperature sensor!...621
6011 Check the Diesel exhaust filter!...623
6012 Air filter dirty!...624
6013 Fault diesel filter...626
6014 Error; water saparator sensor...627
6021 Central lubrication; grease tank empty!...629
6022 Central lubrication; no grease supply...630
6200 Augers [left _ right] operating with ultrasonic sensors...632
6201 Augers [left _ right] operating without ultrasonic sensors!...633
6210 Conveyors [left _ right] operating with ultrasonic sensors...635
6211 Conveyors [left _ right] operating without ultrasonic sensors!...636
6220 Error; conveyor sensor [left _ right]!...638
6300 Error; tamper speed sensor...640
7001 Undefined error!...642
7002 [Open circuit _ short-circuit _ surge] Magnet pump left forward drive...643
7003 [Open circuit _ short-circuit _ surge] Magnet pump left reverse drive...645
7004 [Open circuit _ short-circuit _ surge] Magnet pump right forward drive...646
7005 [Open circuit _ short-circuit _ surge] Magnet pump right reverse drive...647
7010 [Open circuit _ short-circuit _ surge] Magnet transport gear stage switching...648
7011 [Open circuit _ short-circuit _ surge] Solenoid; travel drive motor LH...650
7012 [Open circuit _ short-circuit _ surge] Magnet motor drive right...652
7030 [Open circuit _ short-circuit _ surge] Solenoid; tampers...653
7032 [Open circuit _ short-circuit _ surge] Solenoid; vibration...655
7051 [Open circuit _ short-circuit _ surge] Solenoid; screed floating mode...657
7053 [Open circuit _ short-circuit _ surge] Solenoid; screed assist...659
7054 [Open circuit _ short-circuit _ surge] Solenoid; screed load device...661
7055 [Open circuit _ short-circuit _ surge] Solenoid; screed anti-climbing lock...663
7056 [Open circuit _ short-circuit _ surge] Solenoid; screed raise...665
7057 [Open circuit _ short-circuit _ surge] Solenoid; screed lower...667
7058 [Open circuit _ short-circuit _ surge] Solenoid; screed anti-climbing lock...668
7059 [Open circuit _ Short circuit _ Overcurrent] Solenoid; screed raise_lower...670
7061 [Open circuit _ short-circuit _ surge] Magnet screed tensioning device...672
7070 [Open circuit _ short-circuit _ surge] Solenoid; crown control raise...674
7071 [Open circuit _ short-circuit _ surge] Solenoid; crown control lower...676
7080 [Open circuit _ short-circuit _ surge] Solenoid; hopper close...677
7081 [Open circuit _ short-circuit _ surge] Solenoid; hopper open...679
7082 [Open circuit _ short-circuit _ surge] Solenoid; hopper lock RH...680
7083 [Open circuit _ short-circuit _ surge] Solenoid; hopper lock LH...682
7100 [Open circuit _ short-circuit _ surge] Solenoid; auger LH...683
7101 [Open circuit _ short-circuit _ surge] Solenoid; auger RH...685
7102 [Open circuit _ short-circuit _ surge] Solenoid; auger reverse LH...686
7103 [Open circuit _ short-circuit _ surge] Solenoid; auger reverse RH...688
7104 [Open circuit _ short-circuit _ surge] Solenoid; augers lower...689
7105 [Open circuit _ short-circuit _ surge] Solenoid; augers raise...691
7110 [Open circuit _ short-circuit _ surge] Solenoid; conveyor LH...692
7111 [Open circuit _ short-circuit _ surge] Solenoid; conveyor RH...694
7113 [Open circuit _ short-circuit _ surge] Solenoid; conveyor reverse RH...695
7120 [Open circuit _ short-circuit _ surge] Warning flashers Vario screed...696
7121 [Open circuit _ short-circuit _ surge] Solenoid; Variomatic LH retract...698
7122 [Open circuit _ short-circuit _ surge] Solenoid; Variomatic LH extend...700
7123 [Open circuit _ short-circuit _ surge] Solenoid; Variomatic RH retract...701
7124 [Open circuit _ short-circuit _ surge] Solenoid; Variomatic RH extend...702
7140 [Open circuit _ short-circuit _ surge] Magnet extractor!...703
7150 [Open circuit _ short-circuit _ surge] Solenoid; cylinder pressure...705
7160 [Open circuit _ short-circuit _ surge] Solenoid; brake...707
7170 [Open circuit _ short-circuit _ surge] Solenoid; central lubrication system...709
7180 [Open circuit _ short-circuit _ surge] Solenoid; cooling fan drive...711
7190 [Open circuit _ short-circuit _ surge] Solenoid; tow point LH raise...713
7191 [Open circuit _ short-circuit _ surge] Solenoid; tow point LH lower...715
7192 [Open circuit _ short-circuit _ surge] Solenoid; tow point RH raise...716
7193 [Open circuit _ short-circuit _ surge] Solenoid; tow point RH lower...717
7200 [Open circuit _ short-circuit _ surge] Solenoid; warning horn...718
7210 [Open circuit _ short-circuit _ surge] Solenoid; engine starter motor...720
7220 [Open circuit _ short-circuit _ surge] Solenoid; cold start valve...722
7310 Error; protection system 1...724
7311 Error; protection system 2...725
7312 Error; protection system 3...726
7313 Error; protection system 4...727
10001 Restart ECU [x]...728
10020 No valid module number [x]!...729
10100 Standard parameter ECU [x]!...730
13001 Wrong machine model...731
15001 Error could not be entered in error array...732
21001 ECU [x] Temperature [x] °C...733
21100 Module [x] Error; internal voltage measurement [x] V...734
31 - BATTERY...735
Battery; specifications...736
33 - STARTING SYSTEM...738
Starter motor; removing...739
Starter motor; installing...745
36 - OTHER ELECTRICAL EQUIPMENT...748
Emergency stop switch; specifications...749
37 - CABLE; FUSE; RELAY...750
Overview - Image...752
Wiring diagram 01 - Image...755
Wiring diagram 02 - Image...756
Wiring diagram 03 - Image...757
Wiring diagram 04 - Image...761
Wiring diagram 05 - Image...769
Wiring diagram 06 - Image...773
Wiring diagram 07 - Image...775
Wiring diagram 08 - Image...776
Wiring diagram 09 - Image...778
Wiring diagram 10 - Image...779
Wiring diagram screed heating 1 - Image...780
Wiring diagram screed heating 2 - Image...781
Wiring diagram screed heating 3 - Image...783
Wiring diagram screed heating 4 - Image...784
Wiring diagram screed heating 5 - Image...786
Wiring diagram screed heating 6 - Image...787
Wiring diagram screed heating 7 - Image...788
Wiring diagram screed heating 8 - Image...789
Wiring diagram screed heating 9 - Image...790
Overview_{52-14}...794
Overview_{51-49}...797
Overview_{51-25}...800
Wiring diagram 1...803
Wiring diagram 2...806
Wiring diagram 3_{49-48}...809
Wiring diagram 3_{49-24}...812
Wiring diagram 3_{48-58}...815
Wiring diagram 3_{48-34}...818
Wiring diagram 4_{47-57}...821
Wiring diagram 4_{47-32}...824
Wiring diagram 4_{47-08}...827
Wiring diagram 4_{46-43}...830
Wiring diagram 5_{46-01}...833
Wiring diagram 5_{45-36}...836
Wiring diagram 5_{45-12}...839
Wiring diagram 5_{44-47}...842
Wiring diagram 6_{44-10}...845
Wiring diagram 6_{43-45}...848
Wiring diagram 7...851
Wiring diagram 8_{42-33}...854
Wiring diagram 8_{42-08}...857
Wiring diagram 9...860
Wiring diagram 10...863
Wiring diagram screed heating 1...866
Wiring diagram screed heating 2_{39-49}...869
Wiring diagram screed heating 2_{39-24}...872
Wiring diagram screed heating 3...875
Wiring diagram screed heating 4_{38-22}...878
Wiring diagram screed heating 4_{37-57}...881
Wiring diagram screed heating 5...884
Wiring diagram screed heating 6...887
Wiring diagram screed heating 7...890
Wiring diagram screed heating 8...893
Wiring diagram screed heating 9_{35-27}...896
Wiring diagram screed heating 9_{35-06}...899
Wiring diagram screed heating 9_{34-44}...902
Wiring diagram screed heating 9_{34-22}...905
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...908
Main control unit memory battery; replacing...909
4 - POWER TRANSMISSION...912
44 - HYDROSTATIC DRIVE...913
Track motor; replacing...914
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...917
70 - GENERAL...918
Frame and crawler unit...919
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...920
Track tension; adjusting...921
Track chain assembly; removing_{29-58}...923
Track chain assembly; removing_{29-33}...932
Track chain assembly; installing_{28-50}...941
Track chain assembly; installing_{28-24}...949
Road scraper; removing...958
Road scraper; installing...960
Specifications...962
Idler; description...963
Front idler; removing...965
Front idler; installing...970
Assembling the guide sprocket...975
Track pad; removing...978
Track pad; installing...979
Top roller; replacing one...980
Bottom roller; removing...982
Bottom roller; installing...984
Track tension cylinder; replacing...986
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...989
81 - CAB; NAKED; CANOPY...990
Canopy; removing...991
Canopy; installing...994
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...997
90 - GENERAL...998
Hydraulic diagram 01 - Image...999
Hydraulic diagram 02 - Image...1000
Hydraulic diagram 03 - Image...1002
Hydraulic diagram 04 - Image...1003
Hydraulic diagram 05 - Image...1004
Hydraulic diagram 06 - Image...1007
Hydraulic diagram 07 - Image...1011
Hydraulic diagram 08 - Image...1012
Hydraulic diagram 09 - Image...1013
Hydraulic diagram 10 - Image...1014
Hydraulic diagram 13 - Image...1015
Hydraulic diagram 1...1018
Hydraulic diagram 2_{17-18}...1021
Hydraulic diagram 2_{16-56}...1024
Hydraulic diagram 3...1027
Hydraulic diagram 4...1030
Hydraulic diagram 5_{15-20}...1033
Hydraulic diagram 5_{14-55}...1038
Hydraulic diagram 6_{14-18}...1041
Hydraulic diagram 6_{13-53}...1044
Hydraulic diagram 6_{13-28}...1047
Hydraulic diagram 6_{13-04}...1050
Hydraulic diagram 7...1053
Hydraulic diagram 8...1056
Hydraulic diagram 9...1059
Hydraulic diagram 10...1062
Hydraulic diagram 13_{10-37}...1065
Hydraulic diagram 13_{10-15}...1068
Hydraulic diagram 13_{09-54}...1071
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...1074
Valve block; screed anti-climbing lock; specifications...1075
98 - FUNCTION FOR ROAD CONSTRUCTION...1076
Screed; removing_{06-10}...1078
Screed; removing_{05-46}...1087
Screed; installing_{05-12}...1090
Screed; installing_{04-48}...1098
Tow arm; removing_04-02...1102
Tow arm; removing...1104
Tow arm; installing...1106
Auger flight; removing...1108
Auger flight; installing...1111
Auger bearing hanger; removing...1114
Auger bearing hanger; installing...1116
Auger shaft; removing...1119
Auger shaft; installing...1121
Auger bearing; removing...1123
Auger bearing; installing...1127
Auger drive chain; replacing...1132
Auger motor; removing...1137
Auger motor; installing...1142
Conveyor chain; removing...1147
Conveyor chain; installing...1151
Conveyor drive chain; removing...1155
Conveyor drive chain; installing...1157
Conveyor floor plate; removing...1159
Conveyor floor plate; installing...1162
Conveyor drive shaft; removing...1164
Conveyor drive shaft; installing...1173
Conveyor idler assembly; removing...1182
Conveyor idler assembly; installing...1187
Conveyor idler assembly; disassembling and assembling...1192
Conveyor cover; removing...1195
Conveyor cover; installing...1198
Conveyor drive shaft; disassembling and assembling_{50-43}...1201
Conveyor drive shaft; disassembling and assembling_{50-18}...1209
Generator screed heating; specifications...1217
Generator; checking...1218
Generator controller; checking...1224
Heating system; description...1227
Error message in display unit...1230
...
Volvo Tracked Pavers ABG7820, ABG7820B Service Repair Manual
