1980s–1990s Volvo BM A25/5350 B Articulated Dump Truck Service Manual (P/N P90256)

This Volvo Construction Equipment service manual covers 1980s and 1990s Volvo BM A25 and 5350 B articulated dump trucks in 4x4, 6x4, and 6x6 configurations. The service-information sheets are dated February 27–28, 2013, and organized by Volvo function groups from 000 through 951.

• Engine, fuel, and cooling: Engine removal and installation, valve adjustment, injection-pump replacement and timing checks, radiator replacement, and hydraulic fan-drive diagnosis.

• Transmission diagnosis: PT 1050 electrical and hydraulic fault tracing, ZF PR-61 control-unit tests, speed-sensor replacement, and automatic gear-shifting control-system service.

• Dropbox and axles: FL-652 B removal and installation, shaft-seal replacement, differential-lock adjustment, and six-wheel-drive dog-clutch checks.

• Electrical systems: Starting and preheating circuits, alternator-regulator testing, connector pin schedules, central-warning diagnosis, and retarder-specific wiring diagrams.

• Brakes and compressed air: Service-brake bleeding, brake-pad replacement, parking-brake disc service, compressor repair references, and pneumatic valve reconditioning.

• Steering and chassis: Steering-linkage adjustment, valve-centering checks, cylinder reconditioning, hitch-bearing replacement, and bogie suspension repairs.

• Tipping hydraulics: Pump leakage and pressure tests, control-cable adjustment, tipping-limitation checks, telescopic-cylinder reconditioning, and piston-rod seal replacement.

The procedures suit technicians with heavy-equipment service experience and access to the lifting equipment, pressure gauges, and specialist tools specified for the work.

Engine, Fuel System, and Fan Drive

Engine coverage includes separate methods for removing the engine alone or together with the transmission. Mounting diagrams, lubrication specifications, and valve-adjustment instructions support installation and service work.

Fuel-system sections distinguish TD 71 K, low-emission TD 71 K, and non-intercooled TD 71 GA data. They cover air bleeding, injection-pump replacement, throttle controls, and timing checks with calibrating pipe SVO 3198. Higher-precision timing with diesel timing set SVO 3624 is referred to the separate Engine TD 61, TD 71 manual. Injection-pump repair and reconditioning are assigned to an authorized diesel workshop.

Cooling coverage follows the hydraulic fan drive through pressure testing, pump and motor leakage checks, thermostat-valve reconditioning, and fan-motor disassembly. Radiator replacement instructions are also included.

PT 1050 Transmission and FL-652 B Dropbox

The transmission sections explain lock-up, pressure modulation, gear selection, exhaust-brake interaction, and operation with or without the integral retarder. ZF PR-61 is the test instrument used to simulate operating signals and check the electronic control unit. Clutch-combination charts and separate transmission hydraulic diagrams support these tests.

Electrical measurements and hydraulic pressure checks help distinguish an external circuit fault from a control-unit fault before components are replaced. Load-sensor adjustment is treated separately for different serial-number groups; the cautions explain how incorrect linkage adjustment can damage the transmission.

Dropbox procedures cover removal, installation, shaft seals, high/low-range control, and longitudinal differential-lock adjustment. The drivetrain material also includes transverse differential-lock checks, the six-wheel-drive dog clutch, and reconditioning of the hydraulic-pump power take-off.

Wiring, Connectors, and Warning Circuits

The electrical section connects system-specific wiring diagrams with connector schedules, wire markings, color codes, and component locations. Examples include the starting-circuit diagram, central-warning diagrams, and circuit-board fault-tracing examples.

Alternator-regulator tests and load-sensor electrical checks provide component-level diagnosis. Separate retarder and non-retarder circuits help identify the applicable wiring before testing. Workshop-made tool drawings include the E1003 extractor and E616 trolley, alongside component dimension charts and assembly views.

Air-Hydraulic Brakes and Parking Brake

The compressed-air diagram identifies the service-brake circuits, parking brake, differential locks, and auxiliary pneumatic functions. Repair coverage includes brake bleeding, service-pad replacement, parking-brake disc and pad replacement, and brake adjustment.

Reconditioning sections address the spring brake cylinder, parking-brake valve, foot-brake valve, relay valve, blocking valve, and four-way protection valve. Brake-caliper reconditioning is referred to the separate AH 54, 6x6 service manual.

Steering, Hitch Bearings, and Bogie Suspension

Steering diagnosis covers pump leakage, load-sensing and standby pressures, linkage adjustment, and steering-valve centering. The checks address unwanted self-steering as well as weak steering under load.

Steering and frame-joint views accompany bearing, seal, and hitch replacement procedures. Chassis sections cover cross-stay alignment, triangular-stay bearings, bogie rubber bearings, and suspension elements.

Follow the manual’s service-position requirements for steering-joint locking, dump-body support, pressure release, and supported lifting. Battery precautions, R12/R134a refrigerant handling, and hazards from heat-damaged fluorocarbon rubber seals are also covered.

Tipping Hydraulics and Cylinder Repairs

Separate hydraulic descriptions distinguish the earlier and revised 4x4 tipping systems from the 6x4 and 6x6 arrangements. They explain steering priority, powered lowering, hydraulic damping, and tipping limitation where fitted.

Cylinder procedures cover removal, seal replacement, and telescopic-stage reconditioning. The reconditioning notes identify insufficient tube chamfers as a risk to sealing and stripper rings during assembly, with variant-specific fitting sleeves listed for the work.

A Preview of Engine Oil and Mounting Specifications

These examples are a small selection of the capacity and fastening data included in the manual.

The engine oil table distinguishes a total capacity of 19 liters, including the filter, from 17 liters when changing the oil and filter. That distinction helps avoid confusing total system capacity with the service refill amount.

The engine installation specifications list 135 Nm for the engine-to-flywheel-housing connection, alongside separate values for adjacent mounting joints.

PDF Reading, Wiring Detail, and Page Count

Search, navigation, and circuit detail: PDF text search and embedded bookmarks are unavailable. Some internal cross-references display unresolved placeholders. Small wiring labels require zooming, and portions of dense circuit drawings remain faint or incomplete even when enlarged.

Supplied as one printable PDF download with 736 pages, including the service-information sheets, illustrations, tool drawings, and circuit diagrams. The text is primarily English, with some Swedish headings and figure captions.