Volvo A25E Articulated Dump Truck Service Repair Manual Instant Download

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Service Information
Document Title Engine and transmission, removing Function Group 210 Information Type Service Information Date 2014/7/18
Profile ART, A25E GB Profile ART, A25E GB Profile ART, A25E GB Profile ART, A25E GB
Engine and transmission, removing Op nbr
210-073 88830051 Lifting tool This operation
also includes required tools and times for
applicable parts of the following operations
191 Service positions 173 Coolant, changing
? ?

1. Place the machine in service position, see 191
   Service positions
2. Lower the front grill and pump up the engine hood.

• Figure 1 Front grill
• Turn off the electric power with the battery
  disconnect switch.
• Remove the front and rear underbody skid plates.

Figure 2 Underbody skid plates
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• Front underbody skid plate
• Rear underbody skid plate, left
• Rear underbody skid plate, right
• Front cross member
• Rear cross member
• Remove the front and rear cross members. Weight
  approx.15 kg (33 lbs).
• Drain the hydraulic oil tank. Volume, see 030
  Capacities
• The drain nipple is located on the middle of the
  tank by the suction line for the front hydraulic
  pumps.
• NOTE!
• The oil drain hose is inserted in the pipe for
  the ladder on the inside of the front grill.

Figure 3 Draining hydraulic oil tank
WARNING
Risk of burns. The fluid may be hot. 7. Drain
the engine oil. Volume, see 030 Capacities
Figure 4 Draining engine oil 8. Drain the
gearbox oil. Volume, see Capacities
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Figure 5 Draining transmission oil 9. Remove the
cap for the expansion tank.

• Figure 6
• Drain the coolant, see 173 Coolant, changing
• When the expansion tank is empty, open the air
  bleeder nipples on the cooling pipes.

Figure 7 1. Air bleeder nipples 12. Disconnect
the drain hose from the oil sump. Plug and fold
it aside.
4
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Figure 8 13. Mark up and unplug the connectors
for the PWM-valves, PWM2601 and PWM2602, on the
fan pumps.

• Figure 9
• Disconnect the suction hoses (3 pcs.) between the
  hydraulic tank and the pumps.
• NOTE!
• Take care of waste oil and liquids in an
  environmentally safe way.
• Remove the cannon connector from the
  transmission's connector (EH). Remove the main
  oil filter with the bracket.

NOTICE
Protect all surfaces with plastic film or similar.

• Figure 10
• Cannon connector
• Main oil filter with holder

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16. Remove the LS-hoses (2 pcs.) and the
connector for solenoid valve MA9102 See figure.
LS-hose 2 is disconnected on the left rear pump.
Remove the valve block.

• Figure 11
• Solenoid valve MA9102
• LS-hose 1
• 17. Remove the connectors for temperature sensor
  SE4204 and PWM4204 from the retarder valve.

• Figure 12
• SE4204
• PWM4204
• 18. Unplug the connector for sensor SE4307 for
  output speed from the transmission's rear cover.

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Figure 13 1. Rpm sensor SE4307 19. Unplug
connectors for temperature sensors SE2601 and
SE2602. SE2601 is located at the engine's left
front edge and SE2602 is located at the engine's
right front edge. 20. Remove the belt guard.
Figure 14 21. Remove the bolt for the front
radiator bracket.
Figure 15 22. Remove the outer screw for the
headlight, and swing out the headlight and the
radiator.
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Figure 16 23. Disconnect and plug the radiator
hoses between the engine and the radiator.
Figure 17 24. Disconnect connections AL3201,
AL3201 B and the ground cable from the
alternator and unplug connector MA8701 for the AC
compressor.
Figure 18
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1. AL3201
2. AL3201/B2
3. Ground cable
4. MA8701

WARNING

• See "Safety when working with air conditioning",
  section S and Service Manual "Air conditioning
  R134a".
• If the machine is equipped with AC, the belt
  tensioner and compressor have to be removed. Pull
  the compressor slightly forward, then tilt it up
  and back, leave the hoses for the cooling system
  in place on the compressor to avoid refrigerant
  leaks.
• Unplug the connector for sensor SE2603 from the
  expansion tank and remove the expansion tank with
  the bracket. The bolts for the bracket are
  located on the inside of the radiator bow.

Figure 19 1. Connector SE2603 27. Disconnect
the cable connection from the preheating coil as
well as the feed line and signal line from the
compressor.

• Figure 20
• Cable connection
• Feed line
• Signal line

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28. Disconnect the cable connections RE2501 from
the preheating relay.
Figure 21 29. Remove the connector EM from the
control unit's cable harness quick-coupling.
Figure 22 1. Connector 30. Remove the upper
connection to the intercooler.
NOTICE
Always cover open air connections with a plastic
bag and rubber bands. Gravel, dust and other
particles in these connections may result in
engine failure!
Figure 23
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31. Unplug the connector SE2501/2502 from the
sensor on the inlet pipe. Remove the inlet pipe
for the compressor.

• Figure 24
• Sensor SE2501/2502
• Inlet pipe for compressor
• 32. Remove the induction hose for the turbo.

NOTICE
Always cover open air connections with a plastic
bag and rubber bands. Gravel, dust and other
particles in these connections may result in
engine failure!
Figure 25 33. Remove the inlet pipe for the
turbo.
NOTICE
Always cover open air connections with a plastic
bag and rubber bands. Gravel, dust and other
particles in these connections may result in
engine failure!
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Figure 26 34. Disconnect and plug the fuel
hoses.

• Figure 27
• Unplug connectors MA2308/SE2301 and MA2309/SE2302
  from the fuel filter bracket.
• Disconnect the connector EWM2501 from the air
  valve to the EP-governor.
• Remove the turbine housing with the EP-governor.

NOTICE
Always cover open air connections with a plastic
bag and rubber bands. Gravel, dust and other
particles in these connections may result in
engine failure!
Figure 28
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• Clamp against exhaust pipe
• Clamp against turbo housing
• Connection pipe EP-governor
• 38. Mark up and disconnect the radiator hoses for
  cab heat and the radiator hose.

• Figure 29
• Radiator hose for cab heat
• Radiator hose for cab heat
• Radiator hose
• 39. Disconnect the radiator hose on the engine's
  left side.

• Figure 30
• Work in cab
• Remove the floor mat.
• Disconnect air and electrical connections from
  the operator's seat.
• Remove the operator seat. Weight 40 kg (88 lbs).
• Remove the rear and the middle floor plates.
  Weight 25 kg (55 lbs).

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44. Remove the plastic cover from the steering
column.
Figure 31 45. Remove the steering column UJ
locking pin. Remove the bolt and separate the
steering column.
Figure 32 46. Loosen and move aside the
retarder pedal, throttle pedal and diff lock
switch SW4604.
Figure 33 47. Loosen and press down the brake
pedal through the front floor plate without
disconnecting the air connections.
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Figure 34 48. Mark the position of the steering
shaft in relation to the steering gear. Bend down
the striker plates and remove the 2 bolts. Remove
the steering shaft from the steering shaft's
flange.
Figure 35 49. Make sure that the steering shaft
cannot come apart. Use cable ties or
similar. NOTE! It's important to maintain the
relative position of the universal joints.

• Figure 36
• Remove the front floor plate.
• Unplug and mark up the connectors for the brake
  pedal.

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• Figure 37
• SW5205
• SE5202
• SE5204
• SE5203
• 52. Loosen the propeller shaft from the
  transmission. Suspend the propeller shaft in a
  tensioning strap so that it doesn't fall down.

• Figure 38
• Open the battery compartment and pull out the
  transmission dipstick.
• Disconnect the oil filler hose and the pipe for
  the oil level dipstick from the transmission.

Figure 39
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• Pipe, oil level dipstick
• Oil filler hose
• 55. Disconnect the breather hose from the
  transmission.

Figure 40 56. Remove the clamp on the exhaust
pipe at the transmission's trailing edge.
Figure 41 57. Remove the exhaust pipe's front
attachment against the frame.
Figure 42
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1. Front attachment
WARNING
Risk of crushing injuries 58. Raise the front
grill and remove the lock pin and pin for the gas
springs. Disconnect the gas springs from the bows
and lower them. NOTE! Do not walk on the steps
when the gas springs are removed from the bows.
Figure 43 1. Engine bows 59. Disconnect the
front engine bows and fold them aside. 60.
Remove the exhaust pipe.
Figure 44 61. Remove the lower gaiter between
the intercooler and turbo.
NOTICE
Always cover open air connections with a plastic
bag and rubber bands. Gravel, dust and other
particles in these connections may result in
engine failure!
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Figure 45 62. Mark up and disconnect all
cabling from the starter motor.
Figure 46 63. Secure the engine and
transmission with 88830051 Lifting tool. Weight
approx. 1900 kg (4190 lbs).
Figure 47
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1. Remove the bolts for the front engine mount.
2. Remove the bolted joints for the rear engine
   mounts, and remove the engine mounts.

Figure 48 66. Lift the engine and transmission
carefully. Due to the cramped space between the
oil sump and frame, the engine must be tilted at
the rear at the start of the lift. NOTE! Check
that no hoses or cables are damaged.
Figure 49 67. Lift out the engine and
transmission and place the engine on three axle
stands. Weight approx.1900 kg (4180 lbs).
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