Volvo A30C Articulated Dump Truck Service Repair Manual Instant Download

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Service Information
Document Title Description Function Group 200 Information Type Service Information Date 2014/6/26
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Description Articulated Hauler A30C is equipped
with an engine type TD103KBE (serial No.2958, US
60026) and TD104KAE (serial No. 2959, US
60027). The engine is a straight, six-cylinder,
direct-injection, turbocharged diesel engine with
intercooler. The engine type designation, part
and serial numbers are stamped into the left side
of the cylinder block. The cylinder heads, one
for each cylinder, are mutually interchangeable.
The heads have replaceable valve seats and valve
guides for both inlet and exhaust valves. The
valve mechanism receives its movement from the
camshaft via push rods and rocker arms. The
injection pump is equipped with a smoke limiter
in order to limit the engine torque. The
injectors are installed in replaceable copper
sleeves which are pressed into the cylinder head
and in direct contact with the circulating
coolant. For repair work on the engine we refer
to a separate Service Manual, see the Foreword.
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Service Information
Document Title Diagnosis using Service Display Unit Function Group 200 Information Type Service Information Date 2014/6/26
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Diagnosis using Service Display Unit Error
codes The table below shows a summary of error
codes which may appear on the display unit and
the most likely cause of the fault/error. The
following trouble-shooting diagram shows, in
addition to error codes, also error symptoms,
probable error cause and the action required to
rectify the fault as well as a reference to the
service display unit. Error messages
Display Cause Control lamp, malfunction in transmission Central warning
201 Engine pressure ER Electrical fault sensor circuit (SE16)
202 Engine pressure low Too low lubricating oil pressure, engine yes
Trouble-shooting diagram
Error code Error code Symptom Probable error cause Probable error cause Probable error cause Probable error cause Action Action Action Service display screen (figure) No. unit
201 201 Faulty sensor SE16 or Measure resistance in Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1 Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1
Engine oil faulty cable harness to faulty cable harness to faulty cable harness to faulty cable harness to cable harness and check cable harness and check cable harness and check Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1 Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1
pressure, pressure, the same. the same. the same. the same. sensor. sensor. sensor. Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1 Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1
sensor fault Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1 Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1
(SE16) (SE16) Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1 Figure 5.12 Number 23 Normal oil pressure 0 Low oil pressure 1
202 Low engine oil pressure (SE16) 202 Low engine oil pressure (SE16) Lubricating oil pressure too low. Figure 5.12 Number 23 Figure 5.12 Number 23
Normal oil pressure 0 Normal oil pressure 0
Low oil pressure 1 Low oil pressure 1
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Service Information
Document Title Tightening torques Function Group 200 Information Type Service Information Date 2014/6/26
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Tightening torques
Engine
Engine Flywheel housing 140 N m, 14 kgf m (103 lbf ft)
Front engine mounting, see Invalid linktarget Front engine mounting, see Invalid linktarget
Item 1 220 N m, 22 kgf m (162 lbf ft)
Item 2 140 N m, 14 kgf m (103 lbf ft)
Item 3 50 N m, 5 kgf m (37 lbf ft)
Rear engine mounting, see Invalid linktarget Rear engine mounting, see Invalid linktarget
Item 1 85 N m, 8.5 kgf m (63 lbf ft)
Item 2 134 N m, 13.4 kgf m (100 lbf ft)
Item 3 220 N m, 22 kgf m (162 lbf ft)
Item 4 220 N m, 22 kgf m (162 lbf ft)
Figure 1
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Figure 2
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Service Information
Document Title Trouble-shooting Function Group 200 Information Type Service Information Date 2014/6/26
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• Trouble-shooting
• Methods and aids
• When a fault is suspected or found, it is
  important immediately to determine the cause of
  the fault and identify the faulty component.
• Certain faults are indicated by the red central
  warning lamp on the instrument panel lighting up
  at the same time as the buzzer is sounding or in
  that the LED (Light Emitting Diode) on the ECU is
  flashing.
• In case of a warning, the engine should be
  stopped immediately and a service engineer should
  be called. In order to facilitate and make the
  trouble-shooting more efficient, there are a
  number of aids available.
• Contronic Display Unit
• Contronic Service Display Unit 999 3721
• Multimeter 11 666 140
• Multi-pin breaker box 11 668 002
• With the aid of the Service Display Unit it is
  possible to determine sensor faults, engine oil
  pressure and low engine oil pressure.
• In case of a fault/error the Service Display Unit
  will show an error code (ER indication) and a
  reading (value) deviating from the normal. Error
  codes, possible causes of malfunction and
  suitable action are described under Diagnosis
  using Service Display Unit.
• When an error code or a deviating value is shown,
  measuring resistance is used to establish whether
  the fault is in a component e.g. sensor) or if
  the cable harness to the same is faulty.

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Service Information
Document Title Compression test, warm engine Function Group 210 Information Type Service Information Date 2014/6/26
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• Compression test, warm engine
• Op nbr 21002
• 999 6643 Puller
• 999 8009 Adapter
• 998 8539 Compression gauge
• Prerequisite condition The valves are correctly
  adjusted, see Invalid linktarget .
• Place the machine on level ground and apply the
  parking brake.
• Carefully clean around the injectors and at the
  connections for the fuel delivery pipes and the
  leak-off fuel pipes.

WARNING
The fuel delivery pipes are pressure prestressed
and must under no circumstances be bent or
reshaped. If a pressure prestressed fuel delivery
pipe is bent or deformed, there is a great risk
that the pipe will break. A damaged delivery
pipe must always be replaced with a new
pipe! Removing 3. Remove the fuel delivery
pipes.
CAUTION
Place protective caps on all injectors and on the
injection pump connections. 4. Remove the
leak-off fuel pipe.
Figure 1 1. 999 6643 Extractor 5. Remove the
injector for the number 1 cylinder. When
necessary use extractor 999 6643 for taking out
the injector.
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See Invalid linktarget . Make sure that the
copper washer which is positioned between the
injector and the copper sleeve comes out
together with the injector, Invalid linktarget
. If it does not come out, use a hook made from
a piece of wire to get it out.
Figure 2 1. Copper washer 6. Install the
adapter 999 8009 and secure it using the injector
retaining yoke and nut. See Invalid linktarget
. Tightening torque 50 N m (5.0 kgf m) (37 lbf
ft).

• Figure 3
• 1. 999 8009, Adapter
• 2. 999 8539, Compression gauge
• Connect compression gauge 998 8539. See Invalid
  linktarget .
• Pull out the stop button and secure the injection
  pump stop lever in the stop position. This is to
  prevent fuel from running out of the delivery
  valves when the engine is cranked with the
  starter motor.
• Check that the gear selector is in neutral.
• Crank the engine with the starter motor for 5
  seconds.
• Remove the testing equipment and re-install the
  injector together with a new copper washer.
  Tightening torque 50 N m (5.0 kgf m) (37 lbf
  ft).
• Carry out a compression test of cylinders 2, 3,
  4, 5 and 6 in the same way as for cylinder number
  1. Remove the pipe between the turbocharger and
  intercooler when testing cylinder number 6.

11
Normal compression pressure is 2.6 MPa (26 bar)
(377 psi) at 220 rpm.
CAUTION

• Differences of 10 in the compression pressure
  between the cylinders is fully acceptable and
  does not constitute a reason for further action
  as for example valve reconditioning.
• Installing
• Install the leak-off fuel pipe together with new
  copper washers.
• Re-install the pipe between the turbocharger and
  the intercooler.

WARNING

• The fuel delivery pipes are pressure prestressed
  and must under no circumstances be bent or
  reshaped. If a pressure prestressed fuel
  delivery pipe is bent or deformed, there is a
  great risk that the pipe will break. A damaged
  delivery pipe must always be replaced!
• Install the fuel delivery pipes. Observe the
  greatest possible cleanliness and make sure that
  the pipes are not bent or deformed. Tighten the
  pipe nuts.
• Tightening torque 1525 N m (1.52.5 kgf m) (18
  lbf ft).
• Restore the stop function. Start the engine and
  check that there are no leaks.

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Service Information
Document Title Engine and transmission, installing Function Group 210 Information Type Service Information Date 2014/6/26
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• Engine and transmission, installing
• Op nbr 21074
• 999 2754 Lifting tool
• 999 2755 Lifting tool
• 999 2756 Lifting tool
• 999 6052 Lifting tool
• Torque wrench 0400 N m (040 kgf m) (0295 lbf
  ft)
• Connect the lifting device to the engine. Incline
  the engine and transmission to the correct angle.
• Lower the unit and install the engine mountings
  (the front ones first). Tightening torque,
  front 220 N m (22 kgf m) (162 lbf ft).
• Tightening torque, rear 140 N m (14 kgf m) (103
  lbf ft).
• Install the propeller shaft.
• Tightening torque 180 N m (18 kgf m) (133 lbf
  ft).
• Install the components on the transmission

Figure 1 Collecting pipe for leak-off
oil A. Return oil line from fan motor (9/16 UNF)
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• Leak-off oil line from thermostat valve (9/16
  UNF)
• Leak-off oil line from pump 1 (steering and
  tipping system) (7/8 UNF)
• Leak-off oil line from pump 4 (steering and
  tipping system) (7/8 UNF)
• Leak-off oil line from pump 2 (steering and
  tipping system) (7/8 UNF)
• Leak-off oil line from pump 3 (fan drive) (7/8
  UNF)
• Install governor control arm and stop control
  cables. Connect the hoses to the brake pump.
  Install alternator, exhaust pipe and oil
  filters. Install the air cleaner.
• Connect coolant hoses, oil coolers, the fuel
  lines to injection pump.
• Install engine hood and the left side plate.
• Clamp hoses and electrical leads where clamping
  has been removed.
• Open the hydraulic oil tank shut-off valve.
• Fill with coolant, see Invalid linktarget .
  Fill hydraulic oil. See the Operator"s Manual,
  Hydraulic oil, changing. Fill engine oil. See
  the Operator"s Manual, Engine, changing oil.
• Check that there is a sufficient amount of oil in
  the transmission, before starting the engine.

• Figure 2
• On
• Off
• Front guard plate
• Front, transverse member
• Rear guard plate, left
• Rear guard plate, right
• Rear, transverse member
• Start the engine and test the function. Check
  that there are no leaks. Run until warm and check
  the coolant level and the transmission oil
  level.
• Install the front (2) and the rear (5) transverse
  members. Install guard plates (1), (3) and (4),
  see Invalid linktarget .

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21. Close the engine hood and test-run the
machine.
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Service Information
Document Title Engine and transmission, removing Function Group 210 Information Type Service Information Date 2014/6/26
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Engine and transmission, removing Op nbr
21073 999 2754 Lifting tool 999 2755 Lifting
tool 999 2756 Lifting tool 999 6052 Lifting
tool Torque wrench 0400 N m (040 kgf m)
(0295 lbf ft)
WARNING
There is a danger of scalding when removing the
expansion tank cap (radiator cap), as the cooling
system is pressurised when hot. Hot oil may
cause burns.
CAUTION
Plug all pipes, hoses and connections after
disconnection. Removing 1. Place the machine in
the service position.
Figure 1 A. On
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• Off
• Front guard plate
• Front, transverse member
• Rear guard plate, left
• Rear guard plate, right
• Rear, transverse member
• Turn off the current with the battery disconnect
  switch, see Invalid linktarget .
• Open up the engine hood and swing out the
  radiator.

WARNING

• The protecting plate may be full of for instance
  clay and weigh considerable more than 50 kg (110
  lb).
• Lower and remove the front (1) guard plate
  (approx. 50 kg (110 lb)) and the two rear (3, 4)
  guard plates, see Invalid linktarget .
• Remove the front (2) and rear (5) transverse
  members under the engine, weight approx. 30 kg
  (66 lb) each.
• Remove the engine hood and the left side plate.
• Remove the cap from the radiator expansion tank.
• Drain the coolant from the engine, see Invalid
  linktarget .

CAUTION

• Mark where required. Plug all pipes, hoses and
  connections when removing.
• Exposing engine Left side
• Remove the hose between the turbocharger and the
  air cleaner. Remove the flexible hose of the
  exhaust pipe.
• Disconnect the electrical leads and the hoses.
  Remove the alternator, the oil filter and the
  fuel system water trap.
• Disconnect the governor control arm and the stop
  control cable and secure the stop control, see
  Invalid linktarget .

• Figure 2
• 1. Securing the stop control
• Right side
• Disconnect hoses, pipes and electrical leads from
  the engine. Remove the coolant hose.
• Detach the AC-compressor, if installed, without
  opening the system.

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NOTE! Secure the compressor to the frame with
ties or similar.

• Figure 3
• 1. Shut-off valve for hydraulic oil tank
• Close the hydraulic oil tank shut-off valve and
  secure with locking wire or a tie. Detach the
  control cable. See Invalid linktarget .
• Remove the suction lines for hydraulic pumps 1, 2
  and 4, see Invalid linktarget .

Figure 4 Hydraulic pumps on power take-off
F 1.2 and 4 3
Travelling direction Hydraulic pumps (steering
and tipping systems) Hydraulic pump (fan drive)
14. Mark and disconnect the hoses (B, C, D, E and
F) at the collecting pipe, see Invalid
linktarget .

• Figure 5
• Collecting pipe for leak-off oil
• Return oil line from fan motor (9/16 UNF)
• Leak-off oil line from thermostat valve (9/16
  UNF)
• Leak-off oil line from pump 1 (steering and
  tipping system) (7/8 UNF)
• Leak-off oil line from pump 4 (steering and
  tipping system) (7/8 UNF)
• Leak-off oil line from pump 2 (steering and
  tipping system) (7/8 UNF)

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• F. Leak-off oil line from pump 3 (fan drive) (7/8
  UNF)
• Drain the oil from the engine power take-off,
  (approx. 1 litre 0.26 US gal).
• Disconnect the hoses at the front and rear
  hydraulic pumps. Place the hoses so that they are
  not deformed.
• Disconnect the return oil hose at the hydraulic
  tank.
• Remove the engine oil cooler.
• Disconnect the fuel lines at the fuel injection
  pump.
• Exposing transmission
• Remove the two transmission filters.
• Disconnect connector EH, the oil filler pipe, the
  oil dipstick, the hose for the breather filter,
  the connector for the retarder valve and the
  connector for sensor S13.
• Detach the propeller shaft between the
  transmission and the dropbox at the transmission.
  Secure the propeller shaft.

• Figure 6
• Sling
• Ratchet block, 750 kg (1653 lb)
• 24. Connect a lifting device to the engine, see
  Invalid linktarget . The lifting device
  consists of lifting tools 999 2754, 999 2755,
  999 2756 and 999 6052.

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Figure 7 25. Loosen the four mountings for the
engine, see Invalid linktarget and Invalid
linktarget .
Figure 8 1. Parting rear engine mountings
Figure 9 1. Parting at front engine
mountings 26. Balance and incline the unit to
the correct angle and carefully lift out the
engine and the transmission. See Invalid
linktarget .
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Lower the unit to the floor, support it and make
sure that it stands securely. NOTE! Check that no
hoses become deformed.
Figure 10 Lifting engine-transmission unit
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Service Information
Document Title Engine, installing Function Group 210 Information Type Service Information Date 2014/6/26
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• Engine, installing
• Op nbr 21072
• 999 3590 Gear
• Lifting sling
• Ratchet block 750 kg (1653 lb)
• Ratchet block 1500 kg (3307 lb), 2 pcs
• Apply grease to the torque converter centre pin.
  Check the distance between the torque converter
  and transmission. If distance A is greater than
  approx. 89 mm (3.50 in), see Invalid linktarget
  , lift and carefully press back the torque
  converter. The torque converter may have to be
  removed and the cause why it does not go
  sufficiently far in, be investigated.

Figure 1 A. approximately 89 mm (3.50 in) 2.
Connect a lifting device to the engine and lift
it into position in the machine. See Invalid
linktarget . Remove the brace for the torque
converter and carefully push engine and
transmission together.
CAUTION
The pin on the torque converter must be made to
engage with the notch in the drive disc so that
the marking on the torque converter will be
correctly positioned in relation to the injection
pump, see Invalid linktarget . This design is
to make it possible to check the angular advance
mechanism.
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• Figure 2
• Notch
• Pin
• Tighten the bolted joint between the flywheel
  housing and the transmission. Tightening torque
  85 N m (8.5 kgf m) (63 lbf ft).
• Tighten the bolted joint between the drive disc
  and the torque converter. Tightening torque 55
  N m (5.5 kgf m) (41 lbf ft).
• Lift the unit and remove any supports from under
  the transmission.
• Position and tighten down the engine mountings.
• Tightening torque front 220 N m (22.0 kgf m)
  (162 lbf ft), rear 220 N m (22.0 kgf m) (162 lbf
  ft).
• Remove the lifting device.
• Remove the ratchet block between the dropbox and
  the frame.
• Right side of the engine

CAUTION
Install new O-rings. Coat the bolts with locking
fluid (normal). Tightening torque 50 N m (5.0
kgf m) (37 lbf ft).
23
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• Connect the suction lines.
• Open the hydraulic oil tank shut-off valve,
  Invalid linktarget .
• Install the front, transverse member.

Figure 3 1. Shut-off valve for hydraulic oil
tank 15. Connect the return lines to the
collecting pipe between engine and cab. See
Invalid linktarget .

• Figure 4
• 1. Collecting pipe for leak-off oil
• Check that no leads and hoses are loose or
  pinched, clamp when necessary.
• Install the cover plate behind the air cleaner.
  Install the air cleaner and the inlet hose.
• Fill coolant, see Invalid linktarget .
• Fill hydraulic oil. See the Operator"s Manual,
  Hydraulic oil, changing. Fill engine oil. See
  the Operator"s Manual, Engine, changing oil.
• Check that there is a sufficient amount of oil in
  the transmission, before starting the engine.
  Swing in the radiator and tighten down.
• Bleed the fuel system, see Invalid linktarget .
• Start the engine and test the function and check
  for leaks.
• Check the coolant level and the transmission oil
  level, when engine and transmission have been run
  until warm.
• Install guard plates (1), (3) and (4) under the
  engine. See Invalid linktarget .

25
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the link into your browser. The full manual is
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