Articulated Haulers A40F Volvo / A40F FS Volvo Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Articulated Haulers A40F Volvo / A40F FS Volvo, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Articulated Haulers A40F Volvo / A40F 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.
...
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
PRODUCT DETAILS:
Total Pages: 3,732 pages
File Format: PDF (Windows & Mac & Linux)
Language: English
...
TABLE OF CONTENTS
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Information and warning decals......5
Product plates......15
Complete machine; descriptions......18
03 - SPECIFICATIONS......21
Tyre equipment and recommended tyre pressures......22
Weights......24
Tightening torques......25
07 - STANDARD TIME......36
Operation numbers for additional work......37
08 - TOOL......39
88830557 User Instruction......40
88830508 User instruction......50
88830507 User instruction......61
88830386 User instruction......69
88830268 User Instruction......74
88830227_88830228 User instruction......80
Leak detector 951 1207; description......90
Infrared Thermometer......94
E-7030......98
E-2546......100
E-2534......102
E-2529......104
E-2526......106
E-2525......108
E-2519......110
E-2518......112
E-2517......114
E-2501......117
E-2014......119
E-2005......121
E-1763......123
1 - STANDARD PARTS; SERVICE......125
16 - LUBRICANT; FUEL; OTHER FLUID......126
Exhaust heated dump body......127
This statement is only valid for Volvo branded engines......128
Recommended lubricants......131
Grease......136
Coolant......137
Automatic lubrication system......139
17 - SERVICE......141
Transporting the machine......145
Propeller shaft between transmission and dropbox; removing......152
Parking brake; manually releasing......158
Dump body alternative; lowering......160
Recovering and towing......163
Automatic central lubrication filter; replacing......166
Fire suppression system; checking......169
Exhaust heated load body; checking; cleaning and greasing......194
Load body rubber cushions clearance; checking......196
Load weighing cable to load cell; checking......198
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{07-42-07}......199
Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{07-42-41}......202
Hydraulic tank sediment; draining......208
Hydraulic oil tank breather filter; replacing......210
Hydraulic oil; changing......213
Hydraulic oil level; checking......216
Cab asbestos filter; replacing......217
Cab main filter; replacing......219
Cab prefilter; replacing......221
Alternative exit; checking......223
Tyre wear and air pressure; checking......225
Steering joint bearing; checking......227
Frame joint bearings clearance; checking......231
Frame extension bolted joints torque; checking......234
Secondary steering; checking......236
Steering cylinder bearings clearance; checking......238
Parking brake function; checking......240
Parking brake pads; checking......241
Brake cooling tank return oil filter and magnetic rods; cleaning and replacing_{07-52-35}......243
Brake cooling tank return oil filter and magnetic rods; cleaning and replacing_{07-53-08}......246
Brake cooling oil tank breather filter; replacing......253
Brake cooling oil; changing......255
Brake cooling oil level; checking......259
Brake system pressure oil filter; replacing......260
Service brake disc wear; checking......262
Power take-off suction strainer; cleaning......265
Axle breather filters; replacing......267
Drive axle oil; changing......269
Drive axles leakage; checking......271
Propeller shaft movement; checking......272
Dropbox quick drain valve; replacing......274
Dropbox and front axle; breather filter; replacing......277
Dropbox oil; changing......278
Dropbox leakage; checking......280
Transmission breather filter; replacing......281
Transmission oil filter; replacing......283
Transmission oil; changing......285
Software update; checking......287
MATRIS and Tech Tool; reading......291
Engine and cab heater extra fuel tank breather filter; replacing......293
Engine and cab heater fuel filter; replacing_{08-04-39}......295
Engine and cab heater fuel filter; replacing_{08-05-07}......297
Radiator; cleaning......299
Coolant freezing point; checking......301
Coolant; changing......303
Oil-bath air cleaner reservoir filter insert; cleaning......309
Oil-bath air cleaner reservoir oil; changing......312
Oil-bath air cleaner reservoir oil; checking......315
Engine pre cleaner cyclone type; cleaning......317
Engine air cleaner secondary filter; replacing......320
Engine air cleaner primary filter; replacing......323
Air drier filter; replacing......326
Air drier cartridge; replacing......330
Fuel tank sediment; draining......332
Fuel tank breather filter; replacing_{08-13-17}......334
Fuel tank breather filter; replacing_{08-13-47}......336
Fuel system extra fuel pre- filter; draining......338
Extra fuel prefilter; replacing......340
Fuel filters; replacing......342
Engine oil and filter; changing_{08-16-26}......346
Engine oil and filter; changing_{08-17-00}......349
Engine and dropbox mounts; checking......353
Valves; adjusting_{08-18-50}......356
Drive belts; checking......366
Basic service......368
Lubrication; every 2000 hours......370
Lubrication; every 1000 hours......372
Lubrication; every 500 hours......374
Lubrication; every 250 hours......376
Restoring of the machine......379
Restoring from service position......381
Service position 1 ......383
Maintenance service; every 12000 hours......386
Maintenance service; every 6000 hours......387
Maintenance service; every 4000 hours_{08-25-56}......388
Maintenance service; every 4000 hours_{08-26-25}......391
Maintenance service; every 2000 hours_{08-27-12}......394
Maintenance service; every 2000 hours_{08-27-40}......397
Maintenance service; every 1000 hours......400
Maintenance service; every 500 hours......402
Maintenance service; every 250 hours......404
Maintenance service; every 50 hours......405
Maintenance service; every 10 hours......406
Maintenance service; first 1000 hours......407
Maintenance service; first 100 hours......408
Condition test and maintenance program......409
Tech Tool; operations ......411
Service points......413
Safety when servicing......416
Service_{08-36-31}......418
Service_{08-37-00}......421
19 - GENERAL......423
Decontamination......424
Working in environmentally contaminated areas......428
Safety when working with air conditioning refrigerant......431
Environmentally hazardous fluids......434
Environmentally safe handling......435
Waste handling......437
Environmental handling for the future......441
Environment......443
Health hazards with paint; plastics and rubber......445
Checklist after a fire or heat exposure......448
Fire prevention measures......450
Safety during electric welding......453
Safety when working on the machine's electrical system......455
Safety when handling accumulators......458
Safety when working on hydraulic systems......459
Safety when working on pressurized systems......461
Safety when handling oils and fuel......463
Starting with booster batteries......464
Safety when working with batteries......467
Rules when handling tyres......469
Safety when using lifting equipment......472
Safety when lifting and supporting the machine......474
Checking function......476
Service position 1......478
Safety when handling the machine......481
Safety concerns everybody!......486
FOPS and ROPS......488
CE-marking; EMC-directive......490
2 - ENGINE WITH MOUNTING AND EQUIPMENT......492
21 - ENGINE......493
Engine mounting rear; changing......494
Engine mount rubber cushion; replacing......498
Crankshaft; axial clearance; checking......502
Crankshaft rear oil seal; replacing......507
Crankshaft front oil seal; replacing......514
Camshaft; replacing......519
Camshaft setting; checking......536
Engine timing gear; description......541
Valve cover; installing......544
Valve cover; removing......549
Valves; adjusting_{07-04-12}......552
Valves; adjusting_{07-04-47}......563
Internal Exhaust Gas Recirculation (IEGR); description......574
Cylinder block; description......581
Crankcase ventilation; description......585
Cylinder head; description......588
Cylinder compression; testing......591
Engine; tightening torques......605
Engine rotation speed sensor (camshaft); replacing......616
Engine rotation speed sensor; replacing......621
Engine and transmission; installing......624
Engine and transmission; removing......645
Engine; specifications......668
22 - LUBRICATING SYSTEM......673
Lubrication pressure rocker arm shaft; checking......674
Lubrication oil pressure; checking with pressure gauge......679
Lubrication system; tightening torques......681
Lubrication system; component locations......685
Lubrication oil consumption; checking......688
Lubrication system; specifications......692
Lubrication system; description_{01-46-15}......694
Lubrication system; description_{01-47-43}......700
23 - FUEL SYSTEM......706
Injector sleeves; replacing......707
Overflow valve; replacing......715
Unit injector; replacing......719
Unit injector pretension; adjusting......731
Stall speed; checking......733
Fuel level; description......737
Fuel system; bleeding......739
Fuel pump; inspecting......742
Feed pump pressure; checking......759
Fuel system; component location......761
Carbon dioxide in fuel system; checking......763
Air in fuel system; checking......769
Fuel system; tightening torques......774
Fuel system; specifications......782
Fuel system; description......784
25 - INLET & EXHAUST SYSTEM......790
Cooling fan motor; charge air cooler; checking_adjusting high rpm......791
Cooling fan motor; charge air cooler; checking_adjusting low rpm......796
Charge air cooling system; description......801
Turbocharger; replacing......805
Turbocharger; inspecting......814
Exhaust pressure governor......819
Auxiliary brake (engine braking); description_{05-24-41}......822
Compression brake; description......825
Silencer; replacing......832
Inlet and exhaust system; tightening torques......843
Inlet and exhaust system; component location_{10-50-36}......849
Inlet and exhaust system; component location_{10-51-06}......851
Inlet and exhaust system; specification......853
Inlet and exhaust system; description_{10-52-54}......856
Inlet and exhaust system; description_{10-54-14}......861
Inlet and exhaust system; description_{10-55-36}......866
26 - COOLING SYSTEM......871
Cooling fan motor; radiator; checking high rpm......872
Cooling fan motor; radiator; checking_adjusting low rpm......876
Cooling fan speed control; description......881
Secondary coolant pump; replacing......885
Thermostat; secondary system; description......894
Radiator; adjusting......895
Cooling system pressure; checking......897
Cooling system; tightening torques......899
Cooling system; component location......902
Carbon dioxide in coolant system; checking......904
Cooling system; specification......910
Cooling system; description ......912
27 - ENGINE CONTROL......919
Electronic accelerator pedal; description......920
20 - GENERAL......922
E-ECU MID 128 non-programmed; replacing......923
E-ECU MID 128 pre-programmed; replacing......926
Engine; sensor locations......927
Engine; capacities......930
Tightening torques; engine mounts......931
Tech Tool; operations......933
Engine; description_{07-17-49}......935
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......939
30 - GENERAL......940
SW8701; description and measuring......946
SW5901; description and measuring......948
SW5501; description and measuring......951
SW3801; description and measuring......954
SW3301; description and measuring......956
SWxxxx; Switches general; description and measuring......958
SE9504; description and measuring......960
SE9503; description and measuring......963
SE9301_SE9302; description and measuring......965
SE9105; description and measuring......967
SE9104; description and measuring......970
SE9102_SE9103; description and measuring......972
SE8709; description and measuring......974
SE8708; description and measuring......976
SE8706; description and measuring......978
SE8705; description and measuring......981
SE8702; description and measuring......983
SE8502; description and measuring_{10-00-57}......985
SE8502; description and measuring_{10-02-48}......987
SE8501; description and measuring_{10-04-56}......989
SE8501; description and measuring_{10-06-54}......991
SE8301; description and measuring......993
SE6403; description and measuring......995
SE5901; description and measuring......997
SE5501; description and measuring......999
SE5215 - SE5217; description and measuring......1001
SE5214; description and measuring......1004
SE5207; description and measuring......1006
SE5203_SE5204; description and measuring......1009
SE5201_SE5202; description and measuring......1011
SE4608; description and measuring......1014
SE4607; description and measuring......1016
SE4311; description and measuring......1018
SE4310; description and measuring......1020
SE4309; description and measuring......1022
SE4307; description and measuring......1024
SE4219; description and measuring......1026
SE4218; description and measuring......1028
SE4215; description and measuring......1030
SE4214; description and measuring......1032
SE4213; description and measuring......1034
SE4212; description and measuring......1036
SE4209; description and measuring......1038
SE4208; description and measuring......1040
SE4203; description and measuring......1042
SE4202; description and measuring......1044
SE4201; description and measuring......1046
SE3801; description and measuring......1048
SE2703; description and measuring......1050
SE2702; description and measuring......1053
SE2701; description and measuring......1056
SE2607; description and measuring......1059
SE2606; description and measuring......1062
SE2603; description and measuring......1065
SE2601_SE2602; description and measuring......1068
SE2511_SE2518; description and measuring......1071
SE2509; description and measuring......1074
SE2508; description and measuring......1077
SE2507; description and measuring......1081
SE2502; description and measuring......1084
SE2501; description and measuring......1087
SE2303; description and measuring......1090
SE2302; description and measuring......1093
SE2301; description and measuring......1096
SE2205; description and measuring_{12-32-28}......1099
SE2203; description and measuring......1102
SE2202; description and measuring_{12-38-18}......1105
SAEJ1939_CAN4 Control link; description and measuring......1108
SAE J1939_CAN2 Control link; description and measuring......1111
SAE J1939_CAN1 Control link; description and measuring......1114
SAE J1708_1587 Information link; description and measuring......1117
RExxxx; Relays genaral; description and measuring......1119
RE8701; description and measuring......1121
RE3705; description and measuring_{01-01-16}......1123
RE3705; description and measuring_{01-02-59}......1126
RE2501; description and measuring......1129
PWM9501_PWM9502; description and measuring......1131
PWM9133; description and measuring......1133
PWM5203; description and measuring......1135
PWM5201; description and measuring......1137
PWM4205 - PWM4212; description and measuring......1139
PWM4203; description and measuring......1142
PWM4201; description and measuring......1144
PWM2601_PWM2602; description and measuring......1146
PWM2501; description and measuring......1148
MO8707; description and measuring......1151
MO3301; description and measuring......1154
SID232; description and measuring......1157
SID211; description and measuring......1159
MA9171; description and measuring......1161
MA8701; description and measuring......1163
MA5901; description and measuring......1165
MA5503; description and measuring......1168
MA5501; description and measuring......1171
MA4604_MA4607; description and measuring......1174
MA4604; description and measuring......1176
MA4601 - MA4603; description and measuring......1178
MA2516; description and measuring......1180
MA2505; description and measuring......1183
MA2504; description and measuring......1185
MA2503; description and measuring......1187
MA2301-MA2306; description and measuring......1191
HE2501; description and measuring......1196
FX1090; description and measuring......1199
FX1013; description and measuring......1201
FX1009; description and measuring......1203
FX1008; description and measuring......1205
FX1007; description and measuring......1207
FX1006; description and measuring......1209
FX1005; description and measuring......1211
E-ECU PID158; description and measuring......1213
BB2 Communication bus; description and measuring......1215
BB1 Communication bus; description and measuring......1217
Electronic control system; special tool measuring; ECU......1219
Electronic control system; special tool measuring; general......1221
Component descriptions......1223
Measuring symbols; description......1227
Measuring; general......1231
Electrical cabling and connectors; checking......1233
Error codes; showing......1238
Error causes......1241
Error code and warning levels......1245
Error detection......1248
Electronic Control Unit; Input and Output types......1249
Power supply W-ECU; description and measuring......1252
Power supply V2-ECU; description and measuring......1255
Power supply V-ECU; description and measuring......1258
Power supply HMIM_IC; description and measuring_{03-43-40}......1261
Power supply HMIM_IC; description and measuring_{03-49-45}......1265
Power supply ECC; description and measuring......1270
Tech Tool; operations-......1273
SAE J1939_ CAN-bus (control bus)_{03-58-38}......1275
SAE J1708 (Information bus)_{03-59-22}......1277
Error codes; build-up......1279
Collection of basic data......1284
Troubleshooting strategy......1287
Software parameters; description......1289
Supervision data bus communication; description_{04-05-33}......1297
Stop electronics; description......1300
Start electronics; description......1302
Red extra central warning; description......1304
General vehicle electronics......1306
Data bus system_{04-09-19}......1308
External activation of central warning; description......1310
Control units; voltage supply_{04-10-27}......1312
Tech Tool; Operations......1314
Electrical system; specifications......1316
Service connection and programming connection......1318
System voltage; description......1319
Electrical system; special instructions for servicing; action when working on machine......1321
Electrical system; special instructions for servicing; electrical components; batteries......1323
Electrical system; special instructions for servicing; electronic components......1325
Electrical system; special instructions for servicing; general......1328
31 - BATTERY......1331
Batteries; replacing......1332
Battery; charging......1335
Battery; specifications......1337
Battery; description......1338
32 - ALTERNATOR; CHARGE REGULATOR......1339
Alternator; replacing incl function checking......1340
Alternator; description......1344
Alternator; tightening torques......1347
Alternator; specifications......1348
33 - STARTING SYSTEM......1350
Preheating description......1351
Starter motor; tightening torques......1354
Starter motor; description......1357
Starter motor; specification......1359
35 - LIGHTING......1361
Working lights; description......1362
Tail lamp; replacing......1364
Headlight (low beam 1 pc.); replacing incl. adjusting......1368
Headlight (high beam 1 pc.); replacing incl. adjusting......1372
Light bulb; replacing......1375
Headlights; adjusting......1378
Entrance lighting; description......1382
Lighting; specifications......1385
36 - OTHER ELECTRICAL EQUIPMENT......1387
Tech Tool; programming of machine......1388
Seat belt supervision; description......1390
Door open; description......1392
V-ECU MID 187 pre-programmed; replacing......1395
V-ECU MID 187 non-programmed; replacing......1396
HMIM; MID 140; changing pre-programmed ECU......1399
HMIM; MID 140; changing non-programmed ECU......1400
Engine Gateway MID 165 pre-programmed; replacing......1403
Engine Gateway MID 165 non-programmed; replacing......1405
Control units; changing......1408
Control unit; description_{05-15-09}......1409
Control unit; description_{05-15-35}......1411
Windscreen wiper front motor; replacing......1413
Windscreen wiper motor; tightening torques......1418
Back-up alarm; description......1419
Flasher lamp sidelight glass or bulb; replacing......1421
Flasher lamp front glass or bulb; replacing......1425
Interface for external equipment (Attachment Link); description......1427
Inclination; description......1429
Speed limitation; description......1431
Vehicle speed; description......1435
Delayed stop; description......1437
Anti-theft device; description......1439
37 - CABLE; FUSE; RELAY......1443
Component location 15......1448
Component location 14......1451
Component location 13......1453
Component location 12......1455
Component location 11......1457
Component location 10......1459
Component location 9......1464
Component location 8......1468
Component location 7......1471
Component location 6......1474
Component location 5......1476
Component location 4......1479
Component location 2......1482
Component location 1......1487
Electrical distribution box; description_{03-32-21}......1494
Electrical distribution box; description_{03-33-24}......1503
Electrical distribution box; description_{03-34-24}......1512
Electrical distribution box; description_{03-35-23}......1521
Electrical distribution box; description_{03-36-17}......1530
Electrical distribution box; description_{03-37-12}......1539
Wiring diagram equipment WDE915......1548
Wiring diagram equipment WDE914......1551
Wiring diagram equipment WDE913......1554
Wiring diagram equipment WDE12......1557
Wiring diagram WD905......1560
Wiring diagram WD904......1563
Wiring diagram WD903_{03-41-14}......1566
Wiring diagram WD903_{03-41-37}......1569
Wiring diagram WD902_{03-42-12}......1572
Wiring diagram WD902_{03-42-35}......1575
Wiring diagram WD901_{03-43-09}......1578
Wiring diagram WD901_{03-43-32}......1581
Wiring diagram WD805_{03-44-07}......1584
Wiring diagram WD805_{03-44-30}......1587
Wiring diagram WD804_{03-45-04}......1590
Wiring diagram WD804_{03-45-27}......1593
Wiring diagram WD804_{03-45-50}......1596
Wiring diagram WD803_{03-46-24}......1599
Wiring diagram WD803_{03-46-49}......1602
Wiring diagram WD802_{03-47-23}......1605
Wiring diagram WD802_{03-47-46}......1608
Wiring diagram WD801_{03-48-21}......1611
Wiring diagram WD801_{03-48-44}......1614
Wiring diagram WD504_{03-49-18}......1617
Wiring diagram WD504_{03-49-42}......1620
Wiring diagram WD503_{03-50-17}......1623
Wiring diagram WD503_{03-50-40}......1626
Wiring diagram WD502_{03-51-18}......1629
Wiring diagram WD502_{03-51-42}......1632
Wiring diagram WD501_{03-52-28}......1635
Wiring diagram WD501_{03-52-52}......1638
Wiring diagram WD403_{03-53-27}......1641
Wiring diagram WD403_{03-53-50}......1644
Wiring diagram WD403_{03-54-14}......1647
Wiring diagram WD402_{03-54-48}......1651
Wiring diagram WD402_{03-55-11}......1654
Wiring diagram WD401_{03-55-51}......1657
Wiring diagram WD401_{03-56-15}......1660
Wiring diagram WD330......1663
Wiring diagram WD329_{03-57-24}......1666
Wiring diagram WD329_{03-57-48}......1669
Wiring diagram WD328_{03-58-24}......1672
Wiring diagram WD328_{03-58-48}......1675
Wiring diagram WD327_{03-59-23}......1678
Wiring diagram WD327_{03-59-47}......1681
Wiring diagram WD326......1684
Wiring diagram WD325_{04-00-57}......1687
Wiring diagram WD325_{04-01-20}......1690
Wiring diagram WD324_{04-01-56}......1693
Wiring diagram WD324_{04-02-20}......1696
Wiring diagram WD323_{04-02-55}......1699
Wiring diagram WD323_{04-03-19}......1702
Wiring diagram WD322_{04-03-54}......1705
Wiring diagram WD322_{04-04-18}......1708
Wiring diagram WD321_{04-04-53}......1711
Wiring diagram WD321_{04-05-17}......1714
Wiring diagram WD320_{04-05-52}......1717
Wiring diagram WD320_{04-06-16}......1720
Wiring diagram WD319_{04-07-03}......1723
Wiring diagram WD319_{04-07-27}......1726
Wiring diagram WD318_{04-08-02}......1729
Wiring diagram WD318_{04-08-27}......1732
Wiring diagram WD317_{04-09-03}......1735
Wiring diagram WD317_{04-09-27}......1738
Wiring diagram WD316_{04-10-08}......1741
Wiring diagram WD316_{04-10-32}......1744
Wiring diagram WD315_{04-11-08}......1747
Wiring diagram WD315_{04-11-32}......1750
Wiring diagram WD314_{04-12-08}......1753
Wiring diagram WD314_{04-12-32}......1756
Wiring diagram WD313_{04-13-08}......1759
Wiring diagram WD313_{04-13-32}......1762
Wiring diagram WD312_{04-14-08}......1765
Wiring diagram WD312_{04-14-33}......1768
Wiring diagram WD311_{04-15-08}......1771
Wiring diagram WD311_{04-15-32}......1774
Wiring diagram WD310_{04-16-13}......1777
Wiring diagram WD310_{04-16-37}......1780
Wiring diagram WD309_{04-17-13}......1783
Wiring diagram WD309_{04-17-36}......1786
Wiring diagram WD307_{04-18-12}......1789
Wiring diagram WD307_{04-18-37}......1792
Wiring diagram WD307_{04-19-02}......1795
Wiring diagram WD306_{04-19-37}......1798
Wiring diagram WD306_{04-20-02}......1801
Wiring diagram WD305_{04-20-38}......1804
Wiring diagram WD305_{04-21-02}......1807
Wiring diagram WD304_{04-21-50}......1810
Wiring diagram WD304_{04-22-13}......1813
Wiring diagram WD304_{04-22-44}......1816
Wiring diagram WD303_{04-23-19}......1820
Wiring diagram WD303_{04-23-44}......1823
Wiring diagram WD302_{04-24-20}......1826
Wiring diagram WD302_{04-24-44}......1829
Wiring diagram WD301_{04-25-32}......1832
Wiring diagram WD301_{04-25-56}......1835
Wiring diagram WD220_{04-26-32}......1838
Wiring diagram WD220_{04-26-56}......1841
Wiring diagram WD220_{04-27-26}......1844
Wiring diagram WD208_{04-28-07}......1848
Wiring diagram WD208_{04-28-31}......1851
Wiring diagram WD208_{04-29-02}......1854
Wiring diagram WD207_{04-29-38}......1858
Wiring diagram WD207_{04-30-02}......1861
Wiring diagram WD207_{04-30-33}......1864
Wiring diagram WD206_{04-31-09}......1868
Wiring diagram WD206_{04-31-33}......1871
Wiring diagram WD206_{04-32-05}......1874
Wiring diagram WD205_{04-32-41}......1878
Wiring diagram WD205_{04-33-05}......1881
Wiring diagram WD205_{04-33-37}......1884
Wiring diagram WD204_{04-34-13}......1888
Wiring diagram WD204_{04-34-38}......1891
Wiring diagram WD204_{04-35-09}......1894
Wiring diagram WD203_{04-35-45}......1898
Wiring diagram WD203_{04-36-10}......1901
Wiring diagram WD202_{04-36-46}......1904
Wiring diagram WD202_{04-37-11}......1907
Wiring diagram WD201_{04-37-47}......1910
Wiring diagram WD201_{04-38-11}......1913
Wiring diagrams......1916
ECM (Engine Control Module); I_O list_{04-39-04}......1919
ECC; I_O list......1923
CU3622; I_O list......1926
Electrical component list_{04-51-46}......1930
Electrical component list_{04-52-07}......1941
Explanation of wiring diagrams......1953
Electrical symbols and designations......1955
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......1959
Volvo Co-Pilot; software updating......1960
Volvo Co-Pilot Android software; updating online (OtA)......1965
USB tethering......1970
Volvo Co-Pilot SIM card; installing......1977
Volvo Co-Pilot; replacing......1984
Volvo Co-Pilot application; installing......1989
Volvo Co-Pilot; tightening torques......1994
Volvo Co-Pilot; specifications......1998
Volvo Co-Pilot; component location......2002
Volvo Co-Pilot; software handling......2006
Volvo Co-Pilot; system integration......2010
Volvo Co-Pilot; system overview......2015
Volvo Co-Pilot; introduction......2022
Haul Assist; introduction......2026
Warning screens; general......2031
Information display unit; summary......2033
Information display; cycle info......2035
Information display; settings......2037
Information display; service......2039
Information display; vehicle messages......2042
information display; machine information......2044
Information display; electrical system......2046
Information display; axles _ brakes......2048
Information display; hydraulics......2050
Information display; transmission......2052
Information display; engine......2054
Information display; operating display......2056
Service mode; description......2058
Information display; general......2060
39 - MISCELLANEOUS......2063
CareTrack antenna; replacing......2064
W-ECU; MID142; changing pre-programmed ECU......2072
W-ECU; MID142; changing non-programmed ECU......2073
Voltage converter; specifications......2076
CareTrack system; description......2077
Rear view monitor; service menu......2079
4 - POWER TRANSMISSION......2084
49 - MISCELLANEOUS......2085
Heat exchanger; description......2086
Oil cooler; tightening torques......2088
42 - TRANSMISSION; HYDRAULIC CONTROL......2090
Gear selector......2092
PWM-valve control system; replacing......2096
Transmission oil pressure; checking......2102
Induction sensor for turbine speed; replacing......2105
Induction sensor for output shaft; replacing......2110
Seal for rear output shaft; replacing......2113
Transmission; installing on a non mounted engine......2120
Transmission; removing from a non mounted engine......2125
Transmission; installing......2130
Transmission; removing......2151
Engine and transmission overspeed protection; description......2173
Gear shifting strategy......2176
Gearshifting; description......2183
Cooling system; description......2189
Control system; description......2193
Control system......2202
Oil pump; description......2205
Main oil filter......2207
Oil temperature......2210
Oil level......2214
Lubrication and oil system......2218
Pressure monitor; description-......2222
Sensors; description......2224
Sensors and monitors; description......2232
Clutches; brakes and planet stages; description......2235
Lock-up clutch......2241
Torque converter......2245
Transmission; description......2248
Hydraulic diagram PT......2254
PT Transmission......2257
Transmission; tightening torques......2262
Transmission oil pressure; specifications......2266
Hydraulic transmission; specifications......2270
Hydraulic diagram PT - Image......2271
45 - PROPELLER SHAFT......2272
Propeller shaft between transmission and dropbox; installing......2273
Propeller shaft between transmission and dropbox; removing......2276
Intermediate shaft and_or bearing; replacing (in frame joint)......2281
Propeller shaft; tightening torque......2307
Propeller shaft; description......2309
46 - FRONT AXLE; REAR AXLE......2311
ATC; description......2312
Input shaft seal; replacing......2321
Centre gear; replacing......2328
Hub reduction; installing......2339
Rotation speed sensor; adjusting......2357
Rotation speed sensor; replacing......2363
Output shaft; bearing and seal; replacing......2367
Dog-clutch for drive to rear bogie axle; adjusting......2384
Dog clutch for drive to rear bogie axle; checking and adjusting......2386
Centre gear; replacing-......2400
Centre gear; installing......2416
Centre gear; removing......2423
Hub reduction; removing......2431
Input shaft seal; replacing-......2437
Centre gear ; removing and installing_{02-08-30}......2443
Centre gear ; removing and installing_{02-08-59}......2455
Repair instruction; general......2466
Hub; pressure testing......2468
Drive axles; tightening torques_{02-11-23}......2471
Drive axles; tightening torques_{02-11-45}......2474
Drive axles; description_{02-12-20}......2477
Drive axles; description_{02-12-42}......2481
Axle; specifications_{02-13-28}......2485
Axles; specifications_{02-13-50}......2489
43 - GEARBOX......2493
Dropbox rubber bushing; replacing......2494
Dropbox seal for rear output shaft; replacing......2500
Dropbox seal for front otput shaft; replacing......2507
Checking and adjusting the longitudinal differential lock......2516
Differential lock dropbox sender unit; adjustment......2518
Dropbox; installing......2522
Dropbox; removing......2533
Dropbox; tightening torque......2544
Dropbox; specifications_{02-28-58}......2546
Dropbox; specifications_{02-29-17}......2548
Dropbox; component location......2550
Transfer gearbox; description_{02-31-49}......2557
Transfer gearbox; description_{02-32-17}......2560
48 - POWER TAKE OFF......2567
Power take-off; tightening torque......2568
PTO (Power Take Off); description......2571
40 - GENERAL......2574
Tech Tool; Operations......2575
Drivetrain; description......2577
Drive train capacities_{002-57-50}......2579
Drive train capacities_{002-58-10}......2581
Drive train; specification......2583
5 - BRAKE......2584
59 - MISCELLANEOUS......2585
Retarder; description......2586
Automatic brake description......2589
51 - WHEEL BRAKE......2593
Brake discs; replacing......2594
Stationary service brake test; description......2595
Wheel brake; description......2598
Wear indicator; adjusting......2603
52 - HYDRAULIC BRAKE SYSTEM......2608
Accumulator; discarding......2609
Accumulator (removed) charging pressure; checking......2612
Hydraulic pump; max working pressure; checking and adjusting......2614
Accumulator; replacing......2619
Foot brake valve; replacing......2623
Foot brake valve; description......2628
Brake cooling circulation function; checking......2631
Brake cooling oil system; diagram......2632
Brake cooling system; description......2633
Brake cooling oil tank; description......2640
Pump unit; specification......2642
Brake cooling system; specification......2644
Brake system; pressure releasing......2645
Brake system; bleeding......2647
Hydraulic brake system; pressure build-up......2652
55 - PARKING BRAKE......2656
Load and Dump brake function; checking......2657
Load and Dump brake servo pressure; checking......2659
Load and dump brake working pressure; checking and adjusting......2661
Load and dump brake; description......2665
Parking brake function; checking......2670
Parking brake; adjusting......2672
Parking brake; replacing......2678
Parking brake brake pads; replacing......2679
Parking brake ; replacing brake caliper......2686
Spring brake cylinder; replacing......2695
Parking brake; replacing brake disc......2701
Parking brake; tightening torque......2709
Parking brake; specifications......2711
Parking brake; manually releasing......2713
Parking brake; function description......2715
56 - COMPRESSED-AIR BRAKE......2720
Quick coupling compressed air; replacing......2721
Compressor; replacing......2725
Relief_Cut-in pressure; adjusting......2735
Relief_Cut-in pressure; checking_{11-26-02}......2737
Relief_Cut-in pressure; checking_{11-26-23}......2740
Pressure release......2743
50 - GENERAL......2745
Tech Tool; operations......2746
Compressed air diagram_{11-43-01}......2748
Compressed air diagram_{11-43-20}......2752
Compressed air diagram_{11-43-42}......2756
Hydraulic diagram; brake system......2760
Pressure check connections; description......2761
Compressed air system; description......2763
Braking system; description......2765
Compressed-air system; specifications......2767
Accumulator; specification......2769
Brake pressure......2770
Brakes; specifications......2771
Compressed air system; component location......2773
Brake system; component location......2777
Brake cooling system; capacities......2781
Accumulator; tightening torques......2782
Compressed air diagram - Images......2783
6 - STEERING......2786
64 - STEERING......2787
Auxiliary steering backwards; description......2788
Secondary steering working and stand-by pressure; adjusting......2791
Secondary steering; specification......2796
Secondary steering; description......2797
Secondary steering hydraulic pump; installing......2798
Secondary steering hydraulic pump; removing......2802
Damping cylinder seal; changing......2805
Damping cylinder; checking spring force......2810
Damping cylinder; description......2814
Damping cylinder; specification......2816
Steering cylinder bearings; replacing_{01-41-14}......2817
Steering cylinder bearings; replacing_{01-41-36}......2823
Steering cylinder removed; reconditioning excl replacing bearings......2826
Steering cylinder; installing......2836
Steering cylinder; removing......2841
Steering cylinder; description......2846
Steering cylinder; tightening torques......2849
Steering cylinder; specifications......2850
Steering valve neutral position; checking and adjusting......2851
Steering angle; checking and adjusting......2857
Steering times; checking and adjusting......2859
Steering linkage; checking and adjusting......2862
Steering linkage; tightening torque......2867
Steering gear; replacing......2869
Steering gear; checking and adjusting......2878
Steering gear; specifications......2884
Pressure build up; steering......2886
60 - GENERAL......2889
Steering system; specifications......2890
Steering system; description......2891
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......2900
71 - FRAME......2901
Protective plate; installing......2902
Protective plate; removing......2912
Protective plate; weight......2923
Protecting plate; description......2925
Frame extension; installing......2927
Frame extension; removing......2941
Load unit frame......2954
Tractor unit frame......2956
Frame extension; specification......2958
Frame; description......2959
Frame; weight......2961
74 - FRAME LINK......2962
Steering joint bearing; replacing (Hitch removed)......2963
Steering joint; replacing bearings......2984
Hitch; installing......2993
Hitch; removing......3003
Frame joint bearing; replacing (machine separated)......3011
Frame joint; separating machine......3016
Frame joint; description......3029
Frame joint; tightening torque......3032
Hitch; specifications......3034
75 - AXLE SUSPENSION......3037
Cross stay rubber bushing; replacing......3038
Cross stay; installing......3044
Cross stay; removing......3047
A-frame bushing; front on load unit; changing......3051
A-frame bushing; rear on load unit; changing......3060
Bogie beam rubber bushing (beam removed); changing......3069
Bogie beam rubber spring; changing one side (front)......3072
Bogie beam; changing......3079
Cross stay rubber bushing; replacing-......3089
Cross stay; installing-......3091
Cross stay; removing-......3092
Tractor unit A-frame bushing; replacing......3093
Axle suspension; tightening torque......3101
Axle suspension; description......3104
A–frame......3107
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......3110
Wheel; aligning......3111
Wheel; installing......3115
Wheel; removing......3118
Wheel; tightening torque......3122
72 - SUSPENSION......3124
Suspension; description......3125
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......3126
82 - ENGINE HOOD; MUDGUARD; FOOT STEP......3127
Electric hood pump; changing......3128
Hood pump; oil; changing......3132
Engine hood; installing......3134
Engine hood; removing......3137
Engine hood; description......3141
Hydraulic diagram; hood opening......3144
Engine hood; specification......3146
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......3147
Door window; replacing......3148
Side window; rear; replacing......3154
Side window; replacing......3159
Rear window; replacing......3164
Windscreen; replacing......3170
85 - CAB INTERIOR; UPHOLSTERY......3177
Compressor operator’s seat; replacing......3178
Operator's seat; shock absorber; replacing......3183
Operator's seat; air bellows; replacing_{12-51-00}......3186
Operator's seat; air bellows; replacing_{12-51-23}......3190
Driver's seat; description......3195
Operator's seat; installing_{12-52-15}......3196
Operator's seat; installing_{12-52-37}......3199
Operator's seat; removing_{12-54-01}......3201
Operator's seat; removing_{12-54-23}......3205
87 - AIR CONDITIONING UNIT......3207
Engine- and cab heater; description......3208
Troubleshooting; air conditioning unit (AC)......3212
Receiver; replacing incl draining and filling......3216
Evaporator; cleaning......3220
Evaporator; replacing incl draining and filling......3222
Compressor; replacing incl draining and filling......3231
Refrigerant; filling incl vacuum pumping......3237
Refrigerant; draining......3242
Condenser; replacing incl draining and filling......3247
Cooling unit; performance test......3252
Air-conditioning; component location......3254
AC system; specifications......3256
Air conditioning AC; basic principles......3258
Safety when working with air-conditioning refrigerant......3260
Personal competence and accreditation......3262
Heat control; replacing......3264
Heat control valve; replacing......3267
Fan motor; replacing......3281
Heater core; replacing......3298
ECC MID 146 non-programmed ECU; replacing......3316
ECC MID 146 pre-programmed ECU; replacing......3319
Cab heating_cab ventilation timer; pump; replacing......3320
Cab heat_ventilation timer; description......3327
Climate control system; description......3330
80 - GENERAL......3339
Tech Tool; operations......3340
Cab description......3342
Cabin; specification......3344
81 - CAB; NAKED; CANOPY......3345
Cab; lifting points......3346
Cab; installing......3348
Cab; removing......3365
Instructions for drilling in ROPS structure......3384
83 - DOORS; HATCH; COVER PLATE; (all)......3387
Door lock; replacing......3388
Door; gas spring; replacing......3391
Door; replacing......3393
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......3395
90 - GENERAL......3396
Accumulator; discarding-......3397
V2-ECU; MID 249; changing non-programmed ECU......3400
V2-ECU; MID 249; changing pre-programmed ECU......3403
Tech Tool; Operations-......3404
Hydraulic system; description......3406
Hydraulic system; relieve pressure......3409
Vacuum pump; disconnection......3411
Vacuum pump; connection......3412
Hydraulic system; bleeding......3417
Hydraulic components; storing and transporting......3419
Hydraulic system; repair of hydraulic components in workshop......3421
Hydraulic oil; storing and handling......3423
Hydraulic oil; description......3425
Hydraulic system; capacities......3427
Hydraulic diagram; complete_{12-30-54}......3428
Hydraulic diagram; complete_{12-31-17}......3432
Hydraulic diagram; complete_{12-31-39}......3436
Hydraulic diagram; complete_{12-32-01}......3440
Hydraulic system component location......3444
Hydraulic components; cleanliness when handling......3450
Explanations to hydraulic diagram......3453
Hydraulic diagram; complete - Image......3462
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......3466
Dump function; checking pressure......3467
Dump function; description......3473
Dump lever; specifications......3480
Hydraulic pump (removed); changing shaft seal......3481
Pump regulator; checking......3484
Hydraulic pump; installing......3488
Hydraulic pump; removing......3493
Hydraulic pump; max working pressure; checking and adjusting-......3497
Hydraulic pump; standby pressure; checking and adjusting......3501
Working pumps; checking......3506
Hydraulic pump flow regulation; description......3508
Hydraulic pump; description......3517
Hydraulic pumps; specifications......3520
Dump lever; changing......3523
Steering and dumping valve; removed; reconditioning......3526
Steering and tipping valve; installing......3545
Steering and tipping valve; removing......3552
Steering and dumping valve; description......3559
Steering and dumping valve; tightening torques......3563
Steering and dumping valve; specifications......3565
Hydraulic couplings......3566
Hydraulic connections; tightening torques......3570
Rubber connection; suction line; replacing......3572
Hydraulic tank; description......3575
Pressure check connections; description-......3578
Hydraulic system; work instructions......3582
99 - MISCELLANEOUS......3584
System test......3585
Change of lubrication interval......3588
Bleeding air......3590
Filling lubricant......3592
Automatic lubrication pump unit; reconditioning......3594
Parameter settings......3616
Diagnostic tools; description......3618
Dosage valve; checking internal leakage......3620
Shift valve; checking......3623
Display; description......3628
Lubrication points; central lubrication......3632
Automatic lubrication system; specifications......3634
Dosage valves; description......3636
Pressure monitor; description......3640
Shift valve; description......3642
Pump unit; description......3644
Automatic central lubrication......3647
Fire suppression system; actions after activation......3651
Fire suppression system; actions after manual activation......3678
Fire suppression system; connecting and disconnecting......3707
Fire suppression system; component description......3712
Fire suppression system; functional description......3721
Fire suppression system; component location......3729
Fire suppression system; specification......3731
Fire Suppression System; tightening torques......3733
Steering and dumping valve; overview illustration......3735
Hydraulic pressure; specifications......3738
94 - UNIT; LOAD HANDLING......3742
Load cell; replacing......3743
Load weighing; calibration......3751
Load weighing; description......3754
95 - LOAD CARRIER......3759
Dump body alternative; lowering......3760
Tailgate; description......3763
Cylinder; rear flap; gas pressure; checking and adjusting......3765
Body angle sensor; replacing......3769
Body angle sensor; calibrating......3775
Dump body joint; changing tipping bearing......3777
Dump body; adjusting against frame......3784
Hoist cylinder removed; reconditioning......3792
Hoist cylinder bearing; changing......3803
Hoist cylinder; installing......3809
Hoist cylinder; removing......3814
Hoist cylinder; description......3820
Tailgate; specifications......3823
Hoist cylinder; specification......3825
Dumping system; specification......3826
Load carrier; specifications......3827
Articulated Haulers A40F Volvo / A40F FS Volvo Service Repair Manual
