Volvo Constructions A45G Articulated Haulers Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo Constructions A45G, A45G FS Articulated Haulers, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Articulated Haulers A45G, A45G FS Volvo 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.
Articulated Haulers A45G Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 4,102 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword....2
0 - GENERAL....3
00 - DESCRIPTION; COMPLETE MACHINE....4
Complete machine; descriptions....5
Product plates....8
Information and warning decals....11
03 - SPECIFICATIONS....23
Tyre equipment and recommended tyre pressures....24
Tightening torques....26
Weights....28
07 - STANDARD TIME....29
Operation numbers for additional work....30
08 - TOOL....32
E-1763....33
E-2005....34
E-2014....35
E-2016....36
E-2501....37
E-2502....38
E-2517....39
E-2518....41
E-2519....42
E-2520....43
E-2525....45
E-2526....46
E-2529....48
E-2534....49
E-2539....50
E-2546....51
E-2548....53
E-7029....55
E-7030....56
Infrared Thermometer....57
Leak detector 951 1207; description....58
88830227_88830228 User instruction....61
88830268 User Instruction....69
88830384 User instruction....74
88830386 User instruction....80
88830507 User instruction....84
88830508 User instruction....90
88830557 User Instruction....100
09 - MISCELLANEOUS....108
Troubleshooting strategy....109
Troubleshooting; assistant devices....110
Collection of basic data....111
Tech Tool; operations ....113
Basic checks....114
Engine; basic check....115
Electrical system; basic check....118
Power transmission; basic check....124
Basic check; transmission....127
Brake system; basic check....128
Parking brake; basic check....132
Steering and hydraulics; basic check....135
1 - STANDARD PARTS; SERVICE....137
16 - LUBRICANT; FUEL; OTHER FLUID....138
AdBlue_DEF....139
Automatic lubrication system....141
Coolant....142
Grease....143
Recommended lubricants....144
Alternative fuels....149
Exhaust heated dump body....152
17 - SERVICE....153
Service....156
Safety when servicing....158
Service points....159
Tech Tool; operations....161
Arrival Inspection; according to Inspection Programme....162
Delivery Inspection; according to Inspection Programme....163
Maintenance of Stored Machines; according to Inspection Programme....164
Condition test and maintenance program....165
Maintenance service; first 100 hours....166
Maintenance service; first 1000 hours....167
Maintenance service; every 50 hours....168
Maintenance service; every 4500 hours....169
Restoring from service position....170
Restoring of the machine....171
Lubrication; every 250 hours....173
Lubrication; every 500 hours....176
Lubrication; every 1000 hours....178
Lubrication; every 2000 hours....180
Basic service....181
Drive belts; checking....183
Engine and dropbox mounts; checking....185
Fuel filters; replacing....188
Extra fuel prefilter; replacing....193
Fuel system extra fuel pre- filter; draining....195
Fuel tank breather filter; replacing....196
Fuel tank sediment; draining....197
Air drier filter; replacing....198
EATS Heat protection; checking....201
Diesel particulate filter; checking and cleaning....203
EATS cooling fan; replacing....211
AdBlue_DEF tank breather filter; replacing....215
Engine air cleaner primary filter; replacing....216
Engine air cleaner secondary filter; replacing....218
Engine pre cleaner cyclone type; cleaning....220
Oil-bath air cleaner reservoir oil; checking....222
Oil-bath air cleaner reservoir oil; changing....224
Oil-bath air cleaner reservoir filter insert; cleaning....227
Coolant; changing....230
Radiator; cleaning....239
Engine and cab heater extra fuel tank breather filter; replacing....240
EGR venturi tube; cleaning....241
MATRIS and Tech Tool; reading....243
Software update; checking....244
Transmission oil; changing....246
Transmission oil filter; replacing....248
Transmission breather filter; replacing....250
Dropbox leakage; checking....251
Dropbox oil; changing....252
Dropbox and front axle; breather filter; replacing....254
Dropbox quick drain valve; replacing....255
Propeller shaft movement; checking....258
Drive axles leakage; checking....260
Drive axle oil; changing....261
Axle breather filters; replacing....263
Power take-off suction strainer; cleaning....265
Service brake disc wear; checking....267
Brake system pressure oil filter; replacing....269
Brake cooling oil level; checking....271
Brake cooling oil; changing....272
Brake cooling oil tank breather filter; replacing....276
Brake cooling tank return oil filter and magnetic rods; cleaning and replacing....277
Parking brake function; checking....282
Parking brake; checking and adjusting....283
Steering cylinder bearings clearance; checking....288
Secondary steering; checking....290
Frame extension bolted joints torque; checking....291
Frame joint bearings clearance; checking....292
Steering joint bearing; checking....294
Tyre wear and air pressure; checking....297
Alternative exit; checking....298
Cab prefilter; replacing....299
Cab main filter; replacing....301
Cab asbestos filter; replacing....303
Hydraulic oil level; checking....304
Hydraulic oil tank breather filter; replacing....305
Hydraulic tank sediment; draining....308
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing....310
Load weighing cable to load cell; checking....315
Load body rubber cushions clearance; checking....316
Exhaust heated load body; checking; cleaning and greasing....318
Fire suppression system; checking....320
Automatic lubrication system filter; replacing....343
Recovering and towing....345
Dump body alternative; lowering....349
Parking brake; manually releasing....351
Propeller shaft between transmission and dropbox; removing....353
Transporting the machine....358
19 - GENERAL....364
CE-marking; EMC-directive....365
FOPS and ROPS....367
Safety concerns everybody!....368
Safety when handling the machine....369
Service position 1....373
Safety when lifting and supporting the machine....376
Safety when using lifting equipment....377
Rules when handling tyres....378
Safety when working with batteries....380
Starting with booster batteries....382
Safety when handling oils and fuel....384
Safety when handling AdBlue_DEF....385
Safety when working on pressurized systems....386
Safety when working on hydraulic systems....387
Safety when handling accumulators....388
Safety when working on the machine's electrical system....389
Safety during electric welding....392
Fire prevention measures....393
Checklist after a fire or heat exposure....395
Health hazards with paint; plastics and rubber....396
Environment....398
Environmental handling for the future....399
Waste handling....400
Environmentally safe handling....401
Environmentally hazardous fluids....403
Safety when working with air conditioning refrigerant....404
Working in environmentally contaminated areas....406
Decontamination....407
2 - ENGINE WITH MOUNTING AND EQUIPMENT....408
20 - GENERAL....409
Engine; description_{08-10-00}....410
Engine; description_{08-09-37}....417
Engine; description_{08-09-15}....423
Tech Tool; operations_{08-08-15}....427
Tech Tool; operations_{08-07-56}....430
Tech Tool; operations_{08-07-37}....432
Tightening torques; engine mounts....434
Engine; capacities....436
Engine; sensor locations....437
E-ECU MID 128 pre-programmed; replacing....440
E-ECU MID 128 non-programmed; replacing_{08-05-37}....441
E-ECU MID 128 non-programmed; replacing_{08-05-15}....444
Engine; reference values....447
21 - ENGINE....450
Engine; specifications....451
Engine and transmission; removing....456
Engine and transmission; installing....485
Engine rotation speed sensor; replacing....512
Engine rotation speed sensor (camshaft); replacing....515
Engine; tightening torques....520
Cylinder compression; testing_{08-00-07}....531
Cylinder compression; testing_{07-59-34}....545
Cylinder compression; testing_{07-59-04}....559
Cylinder head; description....573
Crankcase ventilation; description_{07-57-31}....576
Crankcase ventilation; description_{07-57-09}....582
Crankcase ventilation separator; replacing....585
Cylinder block; description....589
Valve mechanism; specifications....593
Internal Exhaust Gas Recirculation (IEGR); description....596
Valves; adjusting_{07-53-34}....603
Valves; adjusting_{07-53-11}....614
Valve cover; removing....625
Valve cover; installing....628
Engine timing gear; description....633
Camshaft setting; checking....636
Camshaft; replacing....641
Crankshaft front oil seal; replacing....658
Crankshaft rear oil seal; replacing....663
Crankshaft; axial clearance; checking....670
Engine mount rubber cushion; replacing....675
Engine mounting rear; changing....679
22 - LUBRICATING SYSTEM....683
Lubrication system; description....684
Lubrication system; specifications....690
Lubrication oil consumption; checking....692
Lubrication system; component locations....696
Lubrication system; tightening torques....699
Lubrication oil pressure; checking with pressure gauge....703
Lubrication pressure rocker arm shaft; checking....705
23 - FUEL SYSTEM....710
Fuel system; description_{04-35-58}....711
Fuel system; description_{04-34-52}....717
Fuel system; specifications....726
Fuel system; tightening torques....728
Air in fuel system; checking....734
Carbon dioxide in fuel system; checking....739
Fuel system; component location....745
Feed pump pressure; checking....747
Fuel pump; inspecting....749
Fuel system; bleeding....766
Fuel level; description....770
Stall speed; checking....772
Unit injector pretension; adjusting....776
Injectors; checking....778
Yoke; injector; checking....789
Unit injector; replacing_{03-50-15}....794
Unit injector; replacing_{01-50-45}....808
Overflow valve; replacing....814
Injector sleeves; replacing_{12-49-40}....818
Injector sleeves; replacing_{12-46-23}....828
25 - INLET & EXHAUST SYSTEM....837
Inlet and exhaust system; description_{12-38-28}....839
Inlet and exhaust system; description_{12-36-30}....849
Inlet and exhaust system; description_{12-35-06}....854
Inlet and exhaust system; specification_{12-33-22}....859
Inlet and exhaust system; specification_{12-33-04}....861
Inlet and exhaust system; component location....864
Inlet and exhaust system; tightening torques_{12-31-47}....866
Inlet and exhaust system; tightening torques_{12-29-52}....873
Exhaust pipe flexible tube; replacing_{12-28-04}....879
Exhaust pipe flexible tube; replacing_{12-25-37}....884
Exhaust pipe flexible tube; replacing_{12-23-57}....888
Exhaust pipe flexible tube; replacing_{11-51-51}....893
Silencer; replacing....897
Compression brake; description....908
Auxiliary brake (engine braking); description_{10-49-51}....915
Auxiliary brake (engine braking); description_{10-49-30}....917
Exhaust pressure governor....920
Exhaust Aftertreatment System; description....923
Exhaust Aftertreatment System; component location....939
Regeneration process; description....944
AdBlue®_DEF tank; replacing....950
AdBlue®_DEF; draining....959
AdBlue®_DEF quality; checking....963
SCR (Selective catalytic reduction) dosing system; checking....966
AdBlue®_DEF pump unit diagnostics; description....971
Exhaust aftertreatment fuel system diagnostics; description....977
DPF (Diesel particulate filter); checking and cleaning....980
ACM (Aftertreatment control module) non-programmed; replacing....988
ACM (Aftertreatment control module) pre-programmed; replacing....992
NOx sensor; replacing....993
Inlet throttle; replacing....997
High pressure air system pressure; checking....1000
Exhaust aftertreatment system fuel flow; checking....1006
Exhaust aftertreatment system cooling fan; replacing....1011
Cooling fan; description....1016
Cooling fan; specification....1022
AdBlue®_DEF pump unit; replacing....1023
AdBlue®_DEF pump unit; components; replacing....1032
AdBlue®_DEF nozzle; replacing....1039
AdBlue®_DEF tank armature; replacing....1044
AdBlue®_DEF tank armature; cleaning....1054
AdBlue®_DEF tank armature suction filter; replacing....1058
Aftertreatment fuel nozzle; replacing....1061
Aftertreatment fuel nozzle; cleaning....1064
Aftertreatment fuel dosing unit; replacing....1067
AdBlue®_DEF hoses; replacing....1071
AdBlue®_DEF....1079
AdBlue®_DEF tank; cleaning....1084
Turbocharger; replacing....1088
Variable turbocharger actuator; replacing....1097
Charge air cooling system; description....1101
Cooling fan motor; charge air cooler; checking adjusting low rpm....1105
Cooling fan motor; charge air cooler; checking adjusting high rpm....1111
26 - COOLING SYSTEM....1117
Cooling system; description....1118
Cooling system; principle illustrations....1126
Cooling system; specification....1128
Carbon dioxide in coolant system; checking....1130
Cooling system; component location....1136
Cooling system; tightening torques....1138
Coolant with anti-freeze and corrosion protection; recommendation....1141
Cooling system pressure; checking....1144
Radiator; adjusting....1146
Electrical coolant pump; replacing....1148
Thermostat; replacing....1156
Cooling fan speed control; description....1162
Cooling fan motor; radiator; checking adjusting low rpm....1165
Cooling fan motor; radiator; checking high rpm....1171
27 - ENGINE CONTROL....1175
Cruise Control; description....1176
Electronic accelerator pedal; description....1181
29 - MISCELLANEOUS....1183
EGR venturi tube; cleaning....1184
Exhaust Gas Recirculation (EGR); description....1187
Exhaust gas recirculation (EGR); component location....1194
EGR system; tightening torques....1196
EGR cooler; replacing....1198
EGR cooler pressure; testing....1204
EGR valve; replacing....1210
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS....1215
30 - GENERAL....1216
Electrical system; special instructions for servicing; general....1224
Electrical system; special instructions for servicing; electronic components....1227
Electrical system; special instructions for servicing; electrical components; batteries....1230
Electrical system; special instructions for servicing; action when working on machine....1232
System voltage; description....1234
Service connection and programming connection....1236
Electrical system; specifications....1237
Tech Tool; Operations ....1239
Control units; voltage supply_{02-12-16}....1241
Control units; voltage supply_{02-11-53}....1243
Control units; voltage supply_{02-11-30}....1245
External activation of central warning; description....1247
Data bus system_{02-10-43}....1249
Data bus system_{02-10-19}....1251
Data bus system_{02-09-58}....1252
General vehicle electronics....1254
Red extra central warning; description....1256
Start electronics; description....1258
Stop electronics; description....1260
Supervision data bus communication; description_{02-07-17}....1262
Supervision data bus communication; description_{02-05-29}....1268
Supervision data bus communication; description_{02-03-41}....1273
Software parameters; description....1278
Troubleshooting strategy....1288
Collection of basic data....1290
Error codes; build-up....1293
SAE J1708 (Information bus)_{01-23-26}....1298
SAE J1708 (Information bus)_{01-23-06}....1300
CAN-bus (control bus)_{01-22-24}....1302
CAN-bus (control bus)_{01-22-02}....1304
Tech Tool; operations....1306
Power supply CU3622; description and measuring....1308
Power supply; ACM (Aftertreatment Control Module); description and measuring....1311
Power supply ECC; description and measuring....1314
Power supply E-ECU; description and measuring....1317
Power supply HMIM_IC; description and measuring....1320
Power supply SID; description and measuring....1324
Power supply V-ECU; description and measuring....1327
Power supply V2-ECU; description and measuring....1330
Power supply W-ECU; description and measuring....1333
Electronic Control Unit; Input and Output types....1336
Error detection....1339
Error code and warning levels....1340
Error causes....1343
Error codes; showing....1347
Electrical cabling and connectors; checking....1350
Measuring; general....1355
Measuring symbols; description....1357
Component descriptions....1361
Electronic control system; special tool measuring; general....1365
Electronic control system; special tool measuring; ECU....1367
Electronic control system; special tool measuring; component....1369
BB1 Communication bus; description and measuring_{08-30-25}....1374
BB1 Communication bus; description and measuring_{08-28-31}....1377
BB1 Communication bus; description and measuring_{08-26-39}....1380
BB1 Communication bus; description and measuring_{08-24-46}....1383
BB2 Communication bus; description and measuring_{08-22-37}....1386
BB2 Communication bus; description and measuring_{08-20-51}....1389
BB2 Communication bus; description and measuring_{08-19-05}....1392
E-ECU PID158; description and measuring....1394
FX1003; description and measuring....1396
FX1004; description and measuring....1398
FX1005; description and measuring....1400
FX1006; description and measuring_{08-14-09}....1402
FX1006; description and measuring_{08-13-49}....1404
FX1007; description and measuring....1406
FX1008; description and measuring....1408
FX1009; description and measuring....1410
FX1010; description and measuring....1412
FX1013; description and measuring....1414
FX1065; description and measuring....1416
FX1066; description and measuring....1418
FX1079; description and measuring....1420
FX1090; description and measuring....1422
HE2501; description and measuring....1424
HE2511; description and measuring....1427
HE2512; description and measuring....1429
MA2301-MA2306; description and measuring....1431
MA2503; description and measuring....1436
MA2504; description and measuring....1440
MA2505; description and measuring....1442
MA2516; description and measuring....1444
MA2517; description and measuring....1447
MA2518; description and measuring....1450
MA2519; description and measuring....1453
MA2520; description and measuring....1456
MA2521; description and measuring....1459
MA2606; description and measuring....1462
MA2608; description and measuring....1465
MA4601 - MA4603; description and measuring....1468
MA4604; description and measuring....1470
MA4607; description and measuring....1472
MA4606; description and measuring....1474
MA5501; description and measuring....1476
MA5503; description and measuring....1478
MA8701; description and measuring....1481
MA9171; description and measuring....1483
MA9506; description and measuring....1485
SID211; description and measuring....1487
SID232; description and measuring....1489
MO2501; description and measuring....1491
MO2503; description and measuring....1494
MO2507; description and measuring....1497
MO2603; description and measuring....1500
MO3301; description and measuring....1504
MO8707; description and measuring....1507
MO8714; description and measuring....1510
PWM2501; description and measuring....1513
PWM2503; description and measuring....1516
PWM2602; description and measuring....1519
PWM4201; description and measuring....1521
PWM4203; description and measuring....1523
PWM4205 - PWM4212; description and measuring....1525
PWM5203; description and measuring....1528
PWM9502; description and measuring....1530
RE2501; description and measuring....1532
RE3705; description and measuring....1534
RE8701; description and measuring....1537
RExxxx; Relays genaral; description and measuring....1539
1587 Information link; description and measuring_{11-01-12}....1541
1587 Information link; description and measuring_{11-00-05}....1544
1587 Information link; description and measuring_{10-58-55}....1546
CAN1 Control link; description and measuring_{10-57-27}....1548
CAN1 Control link; description and measuring_{10-55-31}....1551
CAN1 Control link; description and measuring_{10-54-01}....1554
CAN2 Control link; description and measuring_{10-52-09}....1557
CAN2 Control link; description and measuring_{10-50-35}....1560
CAN2 Control link; description and measuring_{10-48-50}....1563
CAN3 Control link; description and measuring_{10-47-29}....1566
CAN3 Control link; description and measuring_{10-46-20}....1569
CAN3 Control link; description and measuring_{10-45-11}....1572
CAN4 Control link; description and measuring_{10-43-42}....1575
CAN4 Control link; description and measuring_{10-41-40}....1578
CAN4 Control link; description and measuring_{10-40-14}....1581
CAN6 Control link; description and measuring_{10-38-38}....1584
CAN6 Control link; description and measuring_{10-37-10}....1587
CAN6 Control link; description and measuring_{10-35-46}....1590
CAN7 Control link; description and measuring....1593
SE2202; description and measuring....1596
SE2203; description and measuring....1599
SE2205; description and measuring....1602
SE2301; description and measuring....1605
SE2302; description and measuring....1609
SE2303; description and measuring....1612
SE2501; description and measuring....1615
SE2502; description and measuring....1618
SE2507; description and measuring....1621
SE2508; description and measuring....1624
SE2509; description and measuring....1628
SE2510; description and measuring....1631
SE2512; description and measuring....1634
SE2513; description and measuring....1637
SE2514; description and measuring....1639
SE2515; description and measuring....1643
SE2516; description and measuring....1646
SE2518; description and measuring....1649
SE2519; description and measuring....1652
SE2521; description and measuring....1655
SE2522; description and measuring....1658
SE2533; description and measuring....1661
SE2538; description and measuring....1663
SE2539; description and measuring....1667
SE2540; description and measuring....1670
SE2542; description and measuring....1673
SE2545; description and measuring....1676
SE2602; description and measuring....1679
SE2603; description and measuring....1683
SE2606; description and measuring....1686
SE2701; description and measuring....1689
SE2702; description and measuring....1692
SE2703; description and measuring....1695
SE3601; description and measuring....1698
SE3801; description and measuring....1700
SE3803; description and measuring....1702
SE4201; description and measuring....1704
SE4202; description and measuring....1706
SE4203; description and measuring....1708
SE4208; description and measuring....1710
SE4209; description and measuring....1712
SE4212; description and measuring....1714
SE4213; description and measuring....1716
SE4214; description and measuring....1718
SE4215; description and measuring....1720
SE4218; description and measuring....1722
SE4219; description and measuring....1724
SE4307; description and measuring....1726
SE4309; description and measuring....1728
SE4310; description and measuring....1730
SE4311; description and measuring....1732
SE4607; description and measuring....1734
SE4608; description and measuring....1736
SE5202; description and measuring....1738
SE5203; description and measuring....1741
SE5207; description and measuring....1744
SE5214; description and measuring....1747
SE5215 - SE5217; description and measuring....1749
SE5226; description and measuring....1752
SE5501; description and measuring....1755
SE6403; description and measuring....1758
SE8301; description and measuring....1760
SE8501; description and measuring....1762
SE8502; description and measuring....1764
SE8702; description and measuring....1766
SE8705; description and measuring....1768
SE8706; description and measuring....1770
SE8708; description and measuring....1773
SE8709; description and measuring....1775
SE9103; description and measuring....1777
SE9104; description and measuring....1779
SE9105; description and measuring....1781
SE9302; description and measuring....1784
SE9503; description and measuring....1786
SE9504; description and measuring....1788
SWxxxx; Switches general; description and measuring....1791
SW2506; description and measuring....1793
SW3301; description and measuring....1796
SW3801; description and measuring....1798
SW5501; description and measuring....1800
SW5901; description and measuring....1802
SW8701; description and measuring....1804
31 - BATTERY....1806
Battery; description....1807
Battery; specifications....1808
Battery; charging....1809
Batteries; replacing....1811
32 - ALTERNATOR; CHARGE REGULATOR....1814
Alternator; specifications....1815
Alternator; tightening torques....1817
Alternator; description....1819
Alternator; replacing incl function checking....1822
33 - STARTING SYSTEM....1826
Starter motor; specification....1827
Starter motor; description....1828
Starter motor; tightening torques....1830
Starter motor; replacing....1833
Preheating description....1841
35 - LIGHTING....1844
Starter motor; specification....1845
Lighting; specifications....1846
Entrance lighting; description_{07-56-52}....1848
Entrance lighting; description_{07-56-37}....1851
Headlights; adjusting....1854
Light bulb; replacing....1858
Headlight (high beam 1 pc.); replacing incl. adjusting....1861
Headlight (low beam 1 pc.); replacing incl. adjusting....1864
Tail lamp; replacing....1868
Working lights; description....1872
36 - OTHER ELECTRICAL EQUIPMENT....1874
Anti-theft device; description....1876
Delayed stop; description....1880
Vehicle speed; description....1882
Speed limitation; description....1884
Inclination; description....1888
Interface for external equipment (Attachment Link); description....1891
Flasher lamp front glass or bulb; replacing....1893
Flasher lamp sidelight glass or bulb; replacing....1895
Back-up alarm; description....1899
Windscreen wiper motor; tightening torques....1901
Windscreen wiper front motor; replacing....1902
Wiring harnesses and connectors; overview....1907
Wiring harness front pulling unit and lights....1918
Wiring harness engine....1926
Wiring harness exhaust aftertreatment system....1931
Wiring harness transmission....1936
Wiring harness rear pulling unit and hitch....1939
Wiring harness right mudguard....1945
Wiring harness rear view mirrors....1948
Wiring harness left mudguard....1953
Wiring harness cab....1956
Wiring harness cab roof....1964
Wiring harness climate control system....1968
Wiring harness work lights_{07-41-18}....1972
Wiring harness work lights_{07-40-59}....1978
Wiring harness telematic system....1982
Wiring harness haul assist and rear vision system....1985
Wiring harness lubrication system....1993
Wiring harness electric interface....1996
Wiring harness cab heating ventilation timer....2000
Wiring harness engine heater; diesel....2004
Wiring harness loading unit....2010
Wiring harness fuel heater....2013
Wiring harness On Board Weighing system (OBW)....2016
Control unit; description....2023
Control units; changing....2025
Engine Gateway MID 165 non-programmed; replacing....2026
Engine Gateway MID 165 pre-programmed; replacing....2029
HMIM; MID 140; changing non-programmed ECU....2031
HMIM; MID 140; changing pre-programmed ECU....2034
V-ECU MID 187 non-programmed; replacing....2035
V-ECU MID 187 pre-programmed; replacing....2038
Door open; description....2039
Seat belt supervision; description....2042
Tech Tool; programming of machine....2044
37 - CABLE; FUSE; RELAY....2046
Electrical distribution box; description - Image....2050
Electrical symbols and designations....2057
Explanation of wiring diagrams....2061
Electrical component list....2063
ACM; IO list....2078
CU3622; IO list....2082
ECC; IO list....2086
ECM (Engine Control Module); IO list....2089
HMIM; IO LIST....2094
IC (Instrument Cluster); IO list....2097
SID; IO list....2099
V-ECU; IO list....2101
V2-ECU; IO list....2106
W-ECU; IO list....2111
Wiring diagram WD201....2113
Wiring diagram WD202....2117
Wiring diagram WD203....2121
Wiring diagram WD204....2125
Wiring diagram WD205....2129
Wiring diagram WD206....2133
Wiring diagram WD207....2137
Wiring diagram WD208....2141
Wiring diagram WD220....2144
Wiring diagram WD240....2147
Wiring diagram WD241....2151
Wiring diagram WD242....2155
Wiring diagram WD243....2158
Wiring diagram WD244....2162
Wiring diagram WD301....2166
Wiring diagram WD302_{07-17-30}....2169
Wiring diagram WD302_{07-17-16}....2172
Wiring diagram WD303....2175
Wiring diagram WD304....2178
Wiring diagram WD305....2181
Wiring diagram WD306_{07-15-52}....2184
Wiring diagram WD306_{07-15-39}....2188
Wiring diagram WD307_{07-15-13}....2192
Wiring diagram WD307_{07-15-00}....2195
Wiring diagram WD308....2198
Wiring diagram WD309....2201
Wiring diagram WD310....2204
Wiring diagram WD311....2207
Wiring diagram WD312....2210
Wiring diagram WD313....2213
Wiring diagram WD314....2216
Wiring diagram WD315....2220
Wiring diagram WD316....2223
Wiring diagram WD317....2227
Wiring diagram WD318_{07-11-11}....2230
Wiring diagram WD318_{07-10-57}....2234
Wiring diagram WD319....2238
Wiring diagram WD320_{07-10-12}....2241
Wiring diagram WD320_{07-09-59}....2244
Wiring diagram WD321_{07-09-36}....2247
Wiring diagram WD321_{07-09-23}....2250
Wiring diagram WD322_{07-08-58}....2253
Wiring diagram WD322_{07-08-45}....2256
Wiring diagram WD323....2259
Wiring diagram WD324....2262
Wiring diagram WD325....2265
Wiring diagram WD326....2268
Wiring diagram WD327_{07-07-05}....2271
Wiring diagram WD327_{07-06-52}....2275
Wiring diagram WD328....2278
Wiring diagram WD329....2281
Wiring diagram WD330....2284
Wiring diagram WD331....2287
Wiring diagram WD401....2291
Wiring diagram WD402....2295
Wiring diagram WD403_{07-04-16}....2298
Wiring diagram WD403_{07-04-03}....2302
Wiring diagram WD501....2306
Wiring diagram WD502....2309
Wiring diagram WD503....2312
Wiring diagram WD504....2315
Wiring diagram WD801....2318
Wiring diagram WD802....2322
Wiring diagram WD803....2326
Wiring diagram WD804....2329
Wiring diagram WD805....2333
Wiring diagram WD806....2336
Wiring diagram WD901....2340
Wiring diagram WD902....2343
Wiring diagram WD903....2346
Wiring diagram WD904....2349
Wiring diagram WD905....2352
Wiring diagram equipment WDE12....2355
Wiring diagram equipment WDE913....2358
Wiring diagram equipment WDE914....2361
Battery disconnect switch; description....2364
Electrical distribution box; description....2368
Component location 1....2377
Component location 2....2385
Component location 3....2390
Component location 4....2393
Component location 5....2396
Component location 6....2400
Component location 7....2402
Component location 8....2406
Component location 9....2409
Component location 10....2411
Component location 11....2416
Component location 12....2419
Component location 13....2421
Component location 14....2424
Component location 15....2426
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM....2429
Inclination sensor; replacing....2430
Information display; general....2434
Service mode; description....2437
Information display; operating display....2439
Information display; engine....2444
Information display; transmission....2446
Information display; hydraulics....2448
Information display; axles _ brakes....2450
Information display; electrical system....2452
information display; machine information....2454
Information display; vehicle messages....2456
Information display; service....2458
Information display; settings....2461
Information display; cycle info....2463
Information display unit; summary....2465
Warning screens; general....2467
Volvo Co-Pilot; Introduction....2469
Haul Assist; Introduction....2472
Volvo Co-Pilot; system overview....2476
Volvo Co-Pilot; System integration....2482
Volvo Co-Pilot; Software handling....2487
Volvo Co-Pilot; component location....2491
Volvo Co-Pilot; specifications....2494
Volvo Co-Pilot; tightening torques....2497
Volvo Co-Pilot; replacing....2500
Volvo Co-Pilot SIM card; installing....2505
USB tethering....2511
Volvo Co-Pilot Android software; updating online (OtA)....2516
Volvo Co-Pilot; software updating....2520
39 - MISCELLANEOUS....2525
Rear view monitor; service menu....2526
CareTrack system; description....2531
Voltage converter; specifications....2533
W-ECU; MID142; changing non-programmed ECU....2534
W-ECU; MID142; changing pre-programmed ECU....2537
CareTrack antenna; replacing....2538
4 - POWER TRANSMISSION....2546
40 - GENERAL....2547
Drive train; specification....2548
Drive train capacities....2549
Drivetrain; description....2551
Tech Tool; operations....2553
42 - TRANSMISSION; HYDRAULIC CONTROL....2555
Hydraulic diagram PT - image....2557
Gear shifting strategy....2558
Hydraulic transmission; specifications....2572
Transmission oil pressure; specifications....2573
Transmission; tightening torques....2577
PT Transmission....2581
Hydraulic diagram PT....2586
Transmission; description....2589
Torque converter....2595
Lock-up clutch....2598
Clutches; brakes and planet stages; description....2602
Sensors and monitors; description....2608
Sensors; description....2611
Pressure monitor; description....2619
Lubrication and oil system....2621
Oil level....2625
Oil temperature....2629
Main oil filter....2633
Oil pump; description....2636
Control system....2638
Control system; description....2641
Cooling system; description....2650
Gearshifting; description....2654
Engine and transmission overspeed protection; description....2660
Transmission; removing....2663
Transmission; installing....2686
Transmission; removing from a non mounted engine....2710
Transmission; installing on a non mounted engine....2715
Seal for rear output shaft; replacing....2720
Induction sensor for output shaft; replacing....2727
Induction sensor for turbine speed; replacing....2730
Transmission oil pressure; checking....2736
PWM-valve control system; replacing....2739
Gear selector....2745
43 - GEARBOX....2749
Transfer gearbox; description_{01-29-31}....2750
Transfer gearbox; description_{01-29-11}....2757
Transfer gearbox; description_{01-28-52}....2764
Dropbox; component location_{01-27-15}....2767
Dropbox; component location_{01-26-54}....2775
Dropbox; specifications_{01-25-39}....2782
Dropbox; specifications_{01-25-24}....2784
Dropbox; tightening torque....2786
Dropbox; removing....2788
Dropbox; installing....2799
Differential lock dropbox sender unit; adjustment....2810
Checking and adjusting the longitudinal differential lock....2814
Dropbox seal for front otput shaft; replacing....2816
Dropbox seal for rear output shaft; replacing....2825
Dropbox; air damping; checking....2832
Dropbox rubber bushing; replacing....2835
45 - PROPELLER SHAFT....2841
Propeller shaft; description....2842
Propeller shaft; tightening torque....2844
Intermediate shaft and_or bearing; replacing (in frame joint)....2846
Propeller shaft between transmission and dropbox; removing....2869
Propeller shaft between transmission and dropbox; installing....2874
46 - FRONT AXLE; REAR AXLE....2877
Power distribution and ATC; description_{06-29-12}....2878
Power distribution and ATC; description_{06-19-10}....2890
Power distribution and ATC; description_{06-29-10}....2902
Axles; specifications....2913
Drive axles; description....2917
Drive axles; tightening torques....2921
Hub; pressure testing....2924
Repair instruction; general....2927
Centre gear ; removing and installing....2929
Input shaft seal; replacing-....2940
Hub reduction; removing....2947
Centre gear; removing....2953
Centre gear; installing....2961
Dog-clutch for drive to rear bogie axle; adjusting....2968
Input shaft seal; replacing ....2970
Output shaft; bearing and seal; replacing....2978
Rotation speed sensor; replacing....2994
Rotation speed sensor; adjusting....2998
Hub reduction; installing....3004
Input shaft seal; replacing....3022
Differential; checking....3030
48 - POWER TAKE OFF....3031
PTO (Power Take Off); description....3032
Power outlet; specifications....3035
Power take-off; tightening torque....3037
49 - MISCELLANEOUS....3040
Oil cooler; tightening torques_{01-05-09}....3041
Oil cooler; tightening torques_{01-04-52}....3043
Heat exchanger; replacing_{01-04-27}....3045
Heat exchanger; replacing_{01-04-06}....3054
5 - BRAKE....3062
50 - GENERAL....3063
Accumulator; tightening torques....3064
Brake cooling system; capacities....3065
Brake system; component location_{03-29-40}....3066
Compressed air system; component location....3070
Brakes; specifications....3075
Brake pressure....3077
Accumulator; specification....3078
Compressed-air system; specifications_{03-27-44}....3080
Compressed-air system; specifications_{03-27-28}....3082
Braking system; description_{03-27-03}....3084
Compressed air system; description_{03-26-38}....3087
Compressed air system; description_{03-26-21}....3089
Pressure check connections; description....3091
Hydraulic diagram; brake system....3092
Compressed air diagram_{03-25-15}....3093
Compressed air diagram_{03-24-57}....3097
Tech Tool; Operations....3101
51 - WHEEL BRAKE....3103
Wear indicator; adjusting....3104
Wheel brake; description_{03-23-21}....3108
Wheel brake; description_{03-23-02}....3112
Stationary service brake test; description....3116
Wheel brake Teach-in; description....3119
Hill Assist; description....3122
Downhill Speed Control; description....3125
Brake discs; replacing....3130
52 - HYDRAULIC BRAKE SYSTEM....3131
Hydraulic brake system; pressure build-up....3132
Brake system; bleeding....3135
Brake system; pressure releasing....3140
Brake system hydraulic function; checking....3142
Pressure testing....3149
Brake cooling system; specification....3151
Brake cooling pump; specifications....3152
Brake cooling system; component location....3153
Brake cooling system; tightening torques....3155
Brake cooling oil tank; description....3156
Brake cooling system; description....3158
Brake cooling oil system; diagram....3164
Brake cooling circulation function; checking....3165
Brake cooling pump; replacing....3168
Foot brake valve; description....3174
Foot brake valve; replacing....3177
Accumulator; replacing....3181
Hydraulic pump; max working pressure; checking and adjusting....3186
Accumulator (removed) charging pressure; checking....3192
Accumulator; discarding....3194
55 - PARKING BRAKE....3197
Parking brake; description....3198
Parking brake; manually releasing....3203
Parking brake; specifications....3206
Parking brake; tightening torque....3208
Parking brake brake pads; replacing....3210
Parking brake; adjusting....3216
Parking brake function; checking....3222
Parking brake caliper; removing....3224
Parking brake caliper; installing....3229
Parking brake disc; removing....3234
Parking brake disc; installing....3241
Parking brake control valve; replacing....3248
Parking brake pressure; checking....3253
Load and dump brake; description....3257
Load and Dump brake function; checking....3261
Load and dump brake working pressure; checking....3263
56 - COMPRESSED-AIR BRAKE....3267
Pressure release....3268
Cut-in pressure; checking_{03-00-55}....3270
Cut-in pressure; checking_{03-00-37}....3273
Cut-in pressure; adjusting....3276
Compressor; replacing....3278
Quick coupling compressed air; replacing....3288
59 - MISCELLANEOUS....3292
Automatic brake description....3293
Retarder; description....3295
6 - STEERING....3298
60 - GENERAL....3299
Steering system; description....3300
Steering system; specifications....3309
64 - STEERING....3310
Pressure build up; steering....3311
Steering gear; specifications....3314
Steering gear; checking and adjusting....3316
Steering gear; replacing....3322
Steering linkage; tightening torque....3330
Steering linkage; checking and adjusting....3332
Steering times; checking and adjusting....3337
Steering angle; checking and adjusting....3340
Steering valve neutral position; checking and adjusting....3342
Steering cylinder; specifications....3348
Steering cylinder; tightening torques....3349
Steering cylinder; description....3350
Steering cylinder; removing....3353
Steering cylinder; installing....3359
Steering cylinder bearings; replacing_{02-47-26}....3366
Steering cylinder bearings; replacing_{02-47-07}....3369
Damping cylinder; specification....3375
Damping cylinder; description....3376
Damping cylinder; checking spring force....3378
Damping cylinder seal; changing....3382
Secondary steering hydraulic pump; removing....3387
Secondary steering hydraulic pump; installing....3390
Secondary steering; description....3394
Secondary steering; specification....3395
Secondary steering working and stand-by pressure; adjusting....3396
Auxiliary steering backwards; description....3401
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT....3404
71 - FRAME....3405
Frame; weight....3406
Frame; description....3407
Frame extension; specification....3409
Tractor unit frame....3410
Load unit frame....3412
Protecting plate; description....3414
Protective plate; weight....3416
Protective plate; removing....3418
Protective plate; installing....3429
72 - SUSPENSION....3439
Suspension; description....3440
74 - FRAME LINK....3441
Hitch; specifications....3442
Frame joint; tightening torque....3445
Frame joint; description....3447
Frame joint; separating machine....3450
Frame joint bearing; replacing (machine separated)....3463
Hitch; removing....3468
Hitch; installing....3476
Steering joint; replacing bearings....3486
Steering joint bearing; replacing (Hitch removed)....3495
75 - AXLE SUSPENSION....3516
A–frame....3517
Axle suspension; description....3520
Axle suspension; tightening torque....3523
Tractor unit A-frame bushing; replacing....3526
Cross stay; removing ....3534
Cross stay; installing ....3535
Cross stay rubber bushing; replacing ....3536
Bogie beam; changing....3538
Bogie beam rubber spring; changing one side (front)....3548
Bogie beam rubber bushing (beam removed); changing....3555
A-frame bushing; rear on load unit; changing....3558
A-frame bushing; front on load unit; changing....3567
Cross stay; removing....3576
Cross stay; installing....3580
Cross stay rubber bushing; replacing....3583
77 - WHEELS; TRACKS; TYRE; HUB; DRUM....3589
Wheel; tightening torque....3590
Wheel; removing....3592
Wheel; installing....3596
Wheel; aligning....3599
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE....3603
80 - GENERAL....3604
Cabin; specification....3605
Cab description....3606
Tech Tool; operations....3608
81 - CAB; NAKED; CANOPY....3610
Instructions for drilling in ROPS structure....3611
Cab; removing....3614
Cab; installing....3633
Cab; lifting points....3650
82 - ENGINE HOOD; MUDGUARD; FOOT STEP....3652
Engine hood; specification....3653
Hydraulic diagram; hood opening....3654
Engine hood; description....3656
Engine hood; removing....3659
Engine hood; installing....3663
Hood pump; oil; changing....3666
Electric hood pump; changing....3668
83 - DOORS; HATCH; COVER PLATE; (all)....3672
Door; replacing....3673
Door; gas spring; replacing....3675
Door lock; replacing....3677
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING....3680
Windscreen; replacing....3681
Rear window; replacing....3688
Side window; replacing....3694
Side window; rear; replacing....3699
Door window; replacing....3704
85 - CAB INTERIOR; UPHOLSTERY....3710
Operator's seat; removing_{02-09-12}....3711
Operator's seat; removing_{02-08-54}....3713
Operator's seat; installing_{02-08-27}....3717
Operator's seat; installing_{02-08-10}....3719
Driver's seat; description....3722
Operator's seat; air bellows; replacing_{02-07-24}....3723
Operator's seat; air bellows; replacing_{02-07-06}....3728
Operator's seat; shock absorber; replacing....3732
Compressor operator’s seat; replacing....3735
87 - AIR CONDITIONING UNIT....3740
Climate control system; description....3741
Cab heat_ventilation timer; description....3750
Cab heating_cab ventilation timer; pump; replacing....3753
ECC MID 146 pre-programmed ECU; replacing....3760
ECC MID 146 non-programmed ECU; replacing....3761
Heater core; replacing....3764
Fan motor; replacing....3782
Heat control valve; replacing....3799
Heat control; replacing....3813
Personal competence and accreditation....3816
Safety when working with air-conditioning refrigerant....3818
Air conditioning AC; basic principles....3820
Air conditioning; specifications....3822
Cooling system; tightening torques....3824
Air-conditioning; component location....3826
Cooling unit; performance test....3828
Cooling unit; leak detection....3830
Condenser; replacing incl draining and filling....3832
Refrigerant; draining....3837
Refrigerant; filling incl vacuum pumping_{01-58-21}....3842
Refrigerant; filling incl vacuum pumping_{01-58-03}....3847
Compressor; replacing incl draining and filling....3852
Evaporator; replacing incl draining and filling....3858
Evaporator; cleaning....3867
Receiver; replacing incl draining and filling....3869
Troubleshooting; air conditioning unit (AC)....3873
Engine- and cab heater; description....3877
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS....3881
90 - GENERAL....3882
Hydraulic diagram; complete - Image....3883
Hydraulic diagram; complete....3885
Explanations to hydraulic diagram....3893
Hydraulic components; cleanliness when handling....3902
Hydraulic system component location....3905
Hydraulic system; capacities....3911
Hydraulic oil; description....3912
Hydraulic oil; storing and handling....3914
Hydraulic system; repair of hydraulic components in workshop....3916
Hydraulic components; storing and transporting....3918
Hydraulic system; bleeding....3920
Vacuum pump; connection....3922
Vacuum pump; disconnection....3927
Hydraulic system; relieve pressure....3928
Hydraulic system; description....3930
Tech Tool; operations....3933
V2-ECU; MID 249; changing pre-programmed ECU....3934
V2-ECU; MID 249; changing non-programmed ECU....3935
Accumulator; discarding....3938
91 - WORKING HYDRAULIC; SERVO HYDRAULICS....3941
Hydraulic system; work instructions....3942
Pressure check connections; description....3944
Hydraulic tank; description....3946
Hydraulic connections; tightening torques....3948
Steering and dumping valve; specifications....3950
Steering and dumping valve; tightening torques....3951
Steering and dumping valve; description....3953
Dump lever; changing....3957
Hydraulic pumps; specifications....3960
Hydraulic pump; description....3963
Hydraulic pump flow regulation; description....3966
Working pumps; checking....3975
Hydraulic pump; standby pressure; checking and adjusting....3977
Hydraulic pump; max working pressure; checking and adjusting....3983
Pump regulator; checking....3987
Hydraulic pump (removed); changing shaft seal....3991
Hydraulic pump P2; removing....3994
Hydraulic pump P2; installing....3999
Hydraulic pump P3; removing....4005
Hydraulic pump P3; installing....4010
Hydraulic pump P5 and P6; removing....4016
Hydraulic pump P5 and P6; installing....4022
Dump function; description....4028
Dump function; checking pressure....4035
94 - UNIT; LOAD HANDLING....4041
Load weighing; description....4042
Load weighing; calibration....4047
Load cell; replacing....4050
95 - LOAD CARRIER....4058
Dump support; description....4059
Dump boost; description....4062
Load carrier; specifications....4066
Dumping system; specification....4069
Hoist cylinder; specification....4070
Tailgate; specifications....4071
Underhung tailgate; specifications....4073
Hoist cylinder; description....4075
Hoist cylinder; removing....4078
Hoist cylinder; installing....4084
Hoist cylinder bearing; changing_{04-29-43}....4089
Hoist cylinder bearing; changing_{04-29-11}....4095
Dump body; adjusting against frame....4100
Dump body joint; changing tipping bearing....4108
Body angle sensor; calibrating....4115
Body angle sensor; replacing....4117
Cylinder; rear flap; gas pressure; checking and adjusting....4123
Tailgate; description....4126
Body heating; deactivating....4128
Dump body alternative; lowering....4136
99 - MISCELLANEOUS....4139
Hydraulic pressure; specifications....4140
Steering and dumping valve; overview illustration....4144
Fire Suppression System; tightening torques....4147
Fire suppression system; specification....4149
Fire suppression system; component location....4151
Fire suppression system; functional description....4153
Fire suppression system; component description....4160
Fire suppression system; connecting and disconnecting....4169
Fire suppression system; actions after manual activation....4174
Fire suppression system; actions after activation....4203
Automatic central lubrication....4230
Pump unit; description....4234
Shift valve; description....4237
Pressure monitor; description....4239
Dosage valves; description....4241
Automatic lubrication system; specifications....4245
Lubrication points; central lubrication....4247
Display; description....4249
Shift valve; checking....4253
Dosage valve; checking internal leakage....4258
Diagnostic tools; description....4261
Parameter settings....4263
Automatic lubrication pump unit; reconditioning....4265
Filling lubricant....4287
Bleeding air....4289
Change of lubrication interval....4291
System test....4293
Volvo Constructions A45G Articulated Haulers Repair Service Manual
