Volvo ABG5870 Service Repair Manual

Volvo ABG5870 Service Repair Manual

Volvo ABG5870 Repair Manual

ABG5770, ABG5870
ABG6870

Volvo ABG5870 Service Repair Manual

Case IH CX 50 60 70 80 90 100 Repair Service Manual

VOLVO ABG5870 – SERVICE & REPAIR MANUAL

1 – STANDARD PARTS & SERVICE

LUBRICANTS & FLUIDS

• Lubricant, Fuel & Other Fluid Specifications

• Central Lubrication System: Grease Filling, Level Check, Hose Inspection

• Engine Oil: Drain, Fill, Level Check & Filter Replacement

• Hydraulic Oil: Drain, Fill, Level Check & Return Filter Replacement

• Hydraulic Tank Ventilation Filter Replacement

• Coolant: Drain, Fill, Level Check & Freezing Point Test

• Fuel System: Fine Filter & Prefilter Replacement, Air Bleeding, Tank Strainer Cleaning

• Pump Distributor Gear Oil: Drain, Fill, Level Check & Breather Filter Replacement

• Travel Gearbox Oil: Drain & Fill

• Water Separator: Cleaning & Draining

• All-Weather Roof Pump Oil Change

MAINTENANCE SCHEDULES

• Arrival Inspection (Inspection Programme)

• Delivery Inspection (Inspection Programme)

• Maintenance of Stored Machines (Inspection Programme)

• First 100 Hours Service

• Every 10 Hours Service

• Every 100 Hours Service

• Every 500 Hours Service

• Every 1000 Hours Service

• Every 1500 Hours Service

• Every 2000 Hours Service

• Every 3000 Hours Service

• Every 4000 Hours Service

• Maintenance Service (As Required)

ENGINE MAINTENANCE

• Air Intake Hose Replacement

• Air Cleaner Primary Filter: Cleaning & Replacement

• Belt: Tension Check, Adjustment & Replacement

• Mounts Inspection

• Leakage Check

• Hosing Connections Inspection

• Monitoring Warning System Check

• Valve Clearance Adjustment

• Noise Absorbing Mats Replacement

COOLING & EXHAUST SYSTEM

• Charge Air Cooler Draining

• Radiator Cleaning

• Particulate Filter: Cleaning & Inspection

• Diesel Particulate Filter System (Description)

CONVEYOR SYSTEM

• Conveyor Drive Chain: Tension Check, Adjustment & Inspection

• Conveyor Drive Shaft: Inspection & Greasing

• Conveyor Tension: Check & Adjustment

• Conveyor Cover: Installation & Removal

• Conveyor Drive Chain: Installation & Removal

• Conveyor Drive Shaft: Installation & Removal

• Conveyor Idler Assembly: Disassembly & Assembly

AUGER SYSTEM

• Auger Bearing Protector: Checking & Replacement

• Auger Bearings: Check & Greasing

• Auger Box Draining

• Auger Drive Chain Tension: Check & Adjustment

• Auger Flight: Installation & Removal

SCREED SYSTEM

• Screed Control Unit Check

• Generator Screed Heating Belt: Replacement, Tension Check & Adjustment

• Screed: Installation & Removal

• Screed Spacer Blocks: Installation & Removal

• Switch Cabinet Inspection (Gas Screed Heating Specifications)

• Levelling Scales Adjustment

• Front Apron Plate: Installation & Removal

ELECTRICAL & CONTROL SYSTEMS

• Battery Terminals: Cleaning, Charging & Disconnector Switch

• Drive Lever & Operating Keys Check

• Main Control Unit Check

• Switch Cabinet Check

• Control Panel: Parameter Setting & Software Update

• Control Unit Software Update

• EPM II Service Tool

• Pre-programmed ECU Replacement

• Trimming (Offset Adjustment)

• Warning Devices Check

• Road Lighting System Check

• Emergency Stop Switch Specifications

• Engine Control Unit (E-ECU) Specifications

• Vehicle Control Unit (V-ECU) Specifications

HYDRAULIC SYSTEMS

• Hydraulic Cylinders Check

• Hydraulic Hoses Inspection

• Ride-Levelling Cylinders: Adjustment & Check

• Steering: Greasing & Angle Sensor Adjustment

• Towing Arms Bearings Greasing

• Towing Measures

• Hydraulic Filter Specifications

• Hydraulic Oil Tank (Description & Operation)

UNDERCARRIAGE & WHEELS

• Tyres: Air Pressure Check

• Wheel Nuts Torque Check

• Front Wheel: Installation & Removal

• Rear Wheel: Installation & Removal

• Parking Brake Check

• Bolted Joints Torque Check

CLEANING & EXTERNAL MAINTENANCE

• Washing (External Cleaning)

• Radiator Cleaning

• Electric Welding (Safety/Procedures)

• Emulsion Spraying System Cleaning

SAFETY & ENVIRONMENTAL

• Safety During Machine Servicing

• Safety When Working on Hydraulic Systems

• Safety When Working with Batteries

• Safety When Lifting & Supporting the Machine

• Safety When Handling Oils & Fuel

• Working on the Electrical System

• Starting with Booster Batteries

• Decontamination Procedures

• Environmentally Hazardous Fluids (Handling)

• Waste Handling

• Environmental Handling for Future

• Health Hazards (Paint, Plastics & Rubber)

• Safety Concerns (General)

• Checklist After Fire or Heat Exposure

2 – ENGINE WITH MOUNTING & EQUIPMENT

GENERAL

• Engine: Specifications, Description, Capacities

• Engine Belts (Specifications)

• Engine Oil Pressure

• Fuel Tank Capacities

• Injection System Specifications

FUEL SYSTEM

• Fuel System Specifications

INLET & EXHAUST SYSTEM

• Diesel Particulate Filter System (Description)

COOLING SYSTEM

• Thermostat Specifications

Volvo ABG5870 Service Repair Manual

3 – ELECTRICAL, WARNING & INSTRUMENT SYSTEMS

GENERAL

• Instrument & Control Overview

• Instrument & Operating Control Specifications

• Electrical System Instructions

• Inputs & Outputs (Control Units)

• Error Codes: Build-up, Information & Description

• CAN Communication (Data Buses)

• Parameter Codes

• Software Parameters Description

• Report Generation

CONTROL UNIT DIAGNOSTICS

• ECU Configuration & Parameter Errors (10001-10200)

• CAN & Internal Database Errors (10-17)

• External Control Panel Errors (1-3)

• Sensor Errors (4001-4306)

• Diesel Engine Monitoring Errors (5001-5090)

• Charging System Errors (5100-5220)

• Hydraulic System Errors (6001-6022)

• Auger & Conveyor Sensor Errors (6200-6230)

• Solenoid Errors (7001-7210)

• Burner & Protection System Errors (7300-7313)

BATTERY SYSTEM

• Battery: Description, Specifications, Charging

LIGHTING SYSTEM

• Lighting Specifications

OTHER ELECTRICAL EQUIPMENT

• Emergency Stop Switch Specifications

• Engine Control Unit (E-ECU) Specifications

• Vehicle Control Unit (V-ECU) Specifications

CABLES, FUSES & RELAYS

• Battery Disconnector Switch

• Cable Markings

• Central Ground Connections

• Electrical Distribution Box (Fuses & Relays)

• Fuses (Specifications)

WIRING DIAGRAMS

• Complete set of wiring diagrams (1-49)

• Screed Heating Wiring Diagrams (1-10)

4 – POWER TRANSMISSION

GEARBOX

• Travel Gearbox: Assembly, Disassembly, Installation & Removal

HYDROSTATIC DRIVE

• Drive Motor: Installation & Removal

• Travel Drive Calibration

6 – STEERING

STEERING

• Steering Angle Sensor Adjustment

7 – FRAME, SUSPENSION & WHEEL/TRACK UNIT

WHEELS, TRACKS & HUBS

• Front Wheel: Installation & Removal

• Rear Wheel: Installation & Removal

8 – MACHINERY HOUSE, CAB & EXTERIOR TRIM

EXTERIOR TRIM, GLASS & SEALING

• Rear-View Mirror Replacement

9 – HYDRAULIC SYSTEM & ROAD CONSTRUCTION FUNCTIONS

GENERAL HYDRAULICS

• Hydraulic Diagrams (1-11)

WORKING HYDRAULIC & SERVO HYDRAULICS

• Hydraulic Filter Specifications

• Hydraulic Oil Tank (Description & Operation)

ROAD CONSTRUCTION FUNCTIONS

• Auger Flight: Installation & Removal

• Conveyor Cover: Installation & Removal

• Conveyor Drive Chain: Installation & Removal

• Conveyor Drive Shaft: Installation & Removal

• Conveyor Idler Assembly: Disassembly & Assembly

• Error Message Display (Diagnosis)

• Front Apron Plate: Installation & Removal

• Generator Belt Specifications

• Generator Screed Heating Specifications

• Heating System (Description)

• Levelling Scales Adjustment

• Screed: Installation & Removal

• Screed Spacer Blocks: Installation & Removal

SERVICE POSITIONS

• Service Position 1

• Service Position 2

• Service Position 3

ALTERNATIVE FUELS

• Alternative Fuels (Information & Handling)

Volvo ABG5870 Service Repair Manual