Articulated Haulers A40D Volvo Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Articulated Haulers A40D Volvo, with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Construction Articulated Haulers A40D 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.
Articulated Haulers A40D Volvo Service Repair Manual.pdf
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: 3,912
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
000 - GENERAL........2
00 - DESCRIPTION; COMPLETE MACHINE........3
Hydraulics........4
Product identification plates........6
Information and warning decals........8
Steering cylinder; description........11
03 - SPECIFICATIONS........16
Tightening torques........17
Dimensions for A035D with 26.5 R-25 tyres........28
Dimensional diagram A040D........30
Dimensions for A040D with 29.5 R-25 tyres........32
Weights; A040D........34
Capacities; A040D........35
Rocker arm shaft; tightening torques........36
Tightening torques; valve cover........38
Coolant with freezing and corrosion protection........39
Power take-off; tightening torque........40
Tyre equipment and recommended tyre pressures........42
Fuel system; specifications........44
Conversion tables........45
Lubrication system; specifications........50
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION........51
Recovering and towing........52
Lifting machine; A035D........54
Lifting machine; A040D........59
Dealers_retrofitter´s responsibility........64
Appointment and distribution of responsibility........65
07 - STANDARD TIME........66
Operation numbers for additional work........67
08 - TOOL........69
E-1750........70
E-1763........71
E-2000........73
E-2502........75
E-2516........77
E-2519........78
88830051 User Instruction........80
09 - MISCELLANEOUS........90
Troubleshooting; general........91
Troubleshooting strategy........92
Troubleshooting; assistant devices........95
Collection of basic data........96
VCADS Pro service tool; general........99
VCADS Pro; Test........101
VCADS Pro; Error codes........103
VCADS Pro; Calibrating........105
VCADS Pro; Programming........107
VCADS Pro tests........110
Basic checks........114
Engine; basic check........116
Electrical system; basic check........120
Power transmission; basic check........124
Basic check; transmission........126
Brake system; basic check........127
Parking brake; basic check........130
Steering and hydraulics; basic check........132
001 - STANDARD PARTS; SERVICE........134
11 - STANDARD PARTS........135
Service........136
16 - LUBRICANT; FUEL; OTHER FLUID........137
Recommended lubricants........138
Lubrication and service schedules........140
Alternative fuels........141
17 - SERVICE........144
Safety when servicing........145
Warranty inspection........147
Warranty inspection 100 hours........148
Warranty inspection 1000 hours_{09-06-18}........150
Warranty inspection 1000 hours_{09-05-58}........153
Maintenance service; daily........156
Maintenance service; every 050 hours........158
Maintenance service; every 250 hours........161
Maintenance service; every 500 hours........167
Maintenance service; every 1000 hours........181
Maintenance service; every 2000 hours........210
Condition test and maintenance program........256
Lubrication; see lubrication chart........258
Service journal (included in Operator's manual); fill in........259
Coolant; Changing........260
Recovering and towing-........265
Dump body alternative; lowering........267
Mechanical release of parking brake........270
Transporting the machine........272
19 - GENERAL........274
Cleanliness; brake and hydraulic systems........275
Refrigerant for air conditioning........276
CE-marking; EMC-directive........277
Safety concerns everybody!........281
Safety when handling the machine........285
Service position 001........289
Safety when lifting and supporting the machine........291
Safety when using lifting equipment........293
Rules when handling tyres........295
Safety when working with batteries........298
Starting with booster batteries........300
Safety when handling oils and fuel........301
Safety when working on pressurized systems........302
Safety when working on hydraulic systems........304
Safety when handling accumulators_{008-46-17}........306
Safety when handling accumulators_{008-45-55}........307
Safety when working on the machine's electrical system........308
Safety during electric welding........309
Fire prevention measures........310
Checklist after a fire or heat exposure........313
Health hazards with paint; plastics and rubber........316
Environment........319
Environmental handling for the future........321
Waste handling........323
Environmentally safe handling........327
Environmentally hazardous fluids........329
Safety when working with air conditioning refrigerant........332
Working in environmentally contaminated areas........335
Decontamination........338
002 - ENGINE WITH MOUNTING AND EQUIPMENT........342
20 - GENERAL........343
Tightening torques; engine mounts_{008-38-13}........344
Tightening torques; engine mounts_{008-37-51}........346
Engine control unit D012; E–ECU; description of function........348
E–ECU D012; Functions........351
E–ECU D012D; Input and Output terminals........355
Engine D012; description........357
Engine; fill quantities........359
Engine; identification........360
E-ECU MID 128 pre-programmed; replacing_{08-34-15}........362
E-ECU MID 128 pre-programmed; replacing_{08-33-57}........364
E-ECU MID 128 non-programmed; replacing_{08-33-26}........366
E-ECU; changing_{008-33-04}........369
21 - ENGINE........375
Engine; general specifications........377
Cylinder compression; PC test........380
Engine; removing........381
Engine; installing........402
Engine and transmission; removing........419
Engine and transmission; installing........441
Engine speed sensor; changing........458
Engine rotation speed sensor (camshaft); replacing........466
Cylinder compression; testing........473
Tightening torques; valve cover-........482
Tightening torque; cylinder head........483
Cylinder head; description........484
Cylinder block; description........486
Cylinder liner; description........489
Pistons; description........491
Valve mechanism; double rocker arm_{008-20-57}........492
Valve mechanism; specifications_{008-20-35}........494
Valve mechanism; double rocker arm_{008-20-07}........496
Valve mechanism; specifications_{008-19-45}........498
Valve mechanism; description........500
Adjusting; general........503
Internal Exhaust Gas Recirculation (IEGR); description........505
Valves; adjusting_{008-17-12}........511
Valves; adjusting_{008-16-48}........518
Valves; adjusting_{008-16-26}........522
Engine transmission; specification........530
Engine timing gear; description........533
Camshaft; description........535
Camshaft setting; checking........536
Camshaft; replacing........546
Timing gear case new gasket; installing........565
Camshaft; checking........576
Crank mechanism; description........581
Flywheel; tightening torques........583
Crankshaft rear oil seal; replacing........584
Oil sump; tightening torque........591
Oil level sensor; replacing........593
Oil sump gasket; replacing........600
Engine mount rubber cushion; replacing........607
Engine mounting rear; changing........611
22 - LUBRICATING SYSTEM........615
Lubrication system; description_{008-03-52}........616
Lubrication system; description_{008-03-33}........617
Function of the valves........618
Lubrication system; principle........620
Oil pump and oil cooler........622
Lubrication oil pressure; checking with pressure gauge........623
Oil cooler; tightening torques........625
Oil cooler; replacing........628
23 - FUEL SYSTEM........632
Fuel system; specifications ........634
Fuel system; tightening torques........635
Instructions for working with electronic fuel injection........636
Fuel system; description........637
Fuel flow; description........640
Fuel system's components........643
Fuel flow D012C........645
Checking stalling speed-........647
Air in fuel system; checking........650
Cylinder balancing; PC test........654
Carbon dioxide in fuel system; checking........655
Fuel feed pump; specifications........661
Fuel feed pump; description........662
Feed pump pressure; checking........664
Fuel filter housing; description........666
Fuel pump; inspecting........669
Fuel pump (valves); inspecting........674
Fuel system; bleeding_{007-51-25}........676
Fuel system; bleeding_{007-51-03}........678
Feed pressure; PC test........681
Fuel filter; description........682
Water trap; description........684
Filter head D012D; description........685
Checking stalling speed........688
Unit injectors; specifications........691
Unit injector; Bosch; description........692
Unit injector; Delphi; description........694
Function of unit injectors........697
Unit injector; adjusting pretension........702
Unit injector; replacing........705
Injector shut off; manual........714
Overflow valve; checking........715
Injector sleeves; replacing........718
25 - INLET & EXHAUST SYSTEM........726
Air intake and filter........727
Charge-air cooling........728
Preheating coil........729
VEB; description........730
Rocker arm piston; D12C........736
VEB; activation........738
Exhaust pressure governor........740
Turbocharger; specifications........741
Turbocharger........742
Turbocharger; overview illustration........743
Turbocharger; inspecting........745
Turbocharger; replacing........748
Air cleaner; preheating coil; specifications........753
Air cleaner; description........754
Preheating coil; replacing........755
Intercooler; specifications........758
Intercooler; description........759
Charge air cooler; replacing........760
Cooling fan motor; charge air cooler; checking_adjusting low rpm........768
Cooling fan motor; charge air cooler; checking_adjusting high rpm........772
Hydraulic cooling fan control; PC test-........776
26 - COOLING SYSTEM........777
Cooling system; tightening torques........778
Description........780
Cooling system; principle illustrations........782
Coolant circulation; description........784
Cooling system; flushing........786
Cooling system specifications........791
Radiator; description........793
Radiator; removing_{07-29-53}........794
Radiator; removing_{07-29-32}........801
Radiator; installing_{07-28-58}........809
Radiator; mounting_{07-28-36}........816
Coolant filter; changing........824
Radiator; adjusting........827
Coolant; changing........829
Thermostat; description........834
Coolant pump; description........836
Thermostat; primary system........838
Thermostat; primary system; description........839
Thermostat; secondary system........841
Thermostat; secondary system; description........842
Coolant pump; reconditioning........843
Fan system; description........850
Fan belt and_or alternator belt; checking and adjusting tension_{07-23-26}........851
Fan belt and_or alternator belt; checking and adjusting tension_{07-23-04}........854
Cooling fan motor; radiator; checking_adjusting low rpm........856
Cooling fan motor; radiator; checking_adjusting high rpm........860
Hydraulic cooling fan control; PC test........864
003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........865
30 - GENERAL........866
Electrical system; special instructions for servicing; electronic components........889
Electrical system; special instructions for servicing; electrical components; batteries........892
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{02-03-11}........894
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{02-02-41}........896
Electrical system; special instructions for servicing; action when working on machine........898
Data buses; function........900
Service connection and programming connection........902
Software versions and ECUs_part number; general........904
Software versions and ECUs_part number; checking........906
Software versions and ECUs_part number; list........909
Machine status hardware_software........914
Electrical system; specifications........915
Control units; voltage supply........917
Data bus system........919
General vehicle electronics........920
Messages and information content........922
Data buses; voltage levels........924
1F2003; limitation engine protection (EMS)........926
1F2004; engine; status (EMS)_{01-52-42}........928
1F2005; torque limitation; high altitude (EMS)........930
1F2006; engine; service interval (EMS)........932
1F2008; engine speed........934
1F2202; engine oil temperature; warning (EMS)_{01-50-53}........937
1F2202; engine oil temperature; warning (EMS)_{01-50-32}........939
1F2203; engine oil pressure; warning (EMS)_{01-49-59}........941
1F2204; engine oil level........943
1F2301; fuel density (EMS)........944
1F2302; main fuel filter; warning (EMS)........945
1F2303; water in fuel; warning (EMS)........947
1F2503; preheating (EMS)_{01-47-55}........949
1F2503; preheating (EMS)_{01-47-34}........951
1F2505; air filter; pressure-drop (EMS)........953
1F2506; boost pressure; warning (EMS)........955
1F2507; charge-air temperature (EMS)_{01-46-19}........957
1F2601; coolant temperature; warning (EMS)_{01-45-46}........959
1F2601; coolant temperature; warning (EMS)_{01-45-25}........961
1F2602; coolant level (EMS)........963
1F2703; throttle pedal; emergency operation (EMS)........965
1F2704; engine; max. rpm (EMS)........966
1F2705; limitation speed........968
2F4203; gearshifting strategy transmission........969
2F4204; control of transmission_{01-42-08}........972
2F4204; control of transmission_{01-41-28}........976
2F4204; control of transmission_{01-40-47}........980
2F4204; control of transmission_{01-40-07}........984
2F4205; retarder control_{01-39-10}........988
2F4205; retarder control_{01-38-32}........990
2F4206; turbine speed; transmission_{01-37-43}........992
2F4206; turbine speed; transmission_{01-37-22}........993
2F4207; slipping discs; transmission........994
2F4208; oil level in transmission_{01-36-04}........996
2F4208; oil level in transmission_{01-34-29}........999
2F4209; oil temperature in transmission........1001
2F4210; lubrication oil pressure in transmission........1003
2F4211; output speed; transmission........1005
2F4212; overspeeding engine; transmission........1006
2F4213; oil temperature; retarder........1008
2F4214; slipping discs; lock-up........1010
2F4215 transmission; overspeeding........1012
2F4216; input speed; transmission_{01-25-43}........1014
2F4216; input speed; transmission_{01-25-22}........1015
2F4217; lock-up control........1016
2F4218 transmission; solenoid valve defective........1018
2F4219; indication oil change; transmission........1023
2F4301; dropbox control........1024
3F2701; engine acceleration; applied throttle value........1027
3F2702; applied throttle value; limitation........1029
3F8301; door open........1032
4F2701; operating speed engine........1034
5F5201; output pressure brakes........1036
5F5202; brake pressure in accumulator_{01-17-20}........1037
5F5202; brake pressure in accumulator_{01-16-35}........1039
5F5501; parking brake_{01-15-34}........1041
5F5501; parking brake_{01-15-01}........1044
5F5501; parking brake_{01-14-31}........1047
5F5501; parking brake_{01-14-02}........1050
5F5901; load and dump brake........1053
6F2301; main fuel filter........1055
6F2302; fuel level in tank_{01-12-07}........1056
6F2302; fuel level in tank_{01-11-19}........1058
6F2302; fuel level in tank_{01-10-32}........1060
6F2303; fuel consumption........1061
6F2304; water in fuel_{01-08-37}........1063
6F2304; water in fuel_{01-08-06}........1064
7F4601; activation of differential locks and 6–wheel drive........1065
8F3801; language and unit selection........1067
8F3802; date and time........1069
8F3803; display unit lighting_display........1071
8F3804; instrument lighting........1073
8F3805; Inactive warnings_error codes; reset........1074
8F3806; Inactive warnings_error codes; reset........1075
9F2501; preheating induction air........1077
9F2504; air filter........1079
10F5204 brake cooling oil; level in tank_{12-59-56}........1080
10F5204 brake cooling oil; level in tank_{12-59-10}........1082
10F5206 brake cooling oil; circulation........1084
10F9101; engine-dependent steering pressure; hydraulics_{12-55-43}........1088
10F9101; engine-dependent steering pressure; hydraulics_{12-54-52}........1090
10F9101; engine-dependent steering pressure; hydraulics_{12-54-02}........1092
10F9102; ground-dependent steering pressure; hydraulics_{12-53-00}........1094
10F9102; ground-dependent steering pressure; hydraulics_{12-52-11}........1097
10F9103 hydraulic oil; level in tank_{12-51-09}........1100
10F9103 hydraulic oil; level in tank_{12-50-22}........1102
10F9104; shut-off valve suction line; hydraulic oil tank........1104
10F9105; hydraulic oil; temperature........1106
10F9108; hydraulic pump; shut-off_{12-46-25}........1108
10F9108; hydraulic pump; shut-off_{12-46-04}........1109
12F2601; coolant temperature_{12-45-25}........1110
12F2601; coolant temperature_{12-44-02}........1112
12F2602; cooling system; regulation current control_{12-42-16}........1114
12F2602; cooling system; regulation current control_{12-40-19}........1119
12F2602; cooling system; regulation current control_{12-38-21}........1124
12F2603; coolant level........1129
13F3201; system voltage........1130
13F3202; charging monitoring........1132
14F3303; delayed stop; engine........1134
15F3801; inclination indication........1136
17F3801; machine hours_{12-30-48}........1137
17F3801; machine hours_{12-30-13}........1139
17F3801; machine hours_{12-29-38}........1141
17F3802; tachograph........1143
17F3803; machine distance_{12-28-30}........1144
17F3803; machine distance_{12-28-09}........1145
17F3804; machine hours; correction_{12-27-31}........1146
17F3804; machine hours; correction_{12-27-02}........1147
17F3805; machine distance; correction_{12-26-21}........1148
17F3805; machine distance; correction_{12-25-52}........1149
17F9501; travelled distance; operating hours and number of cycles........1150
18F2201; engine oil pressure_{12-24-17}........1152
18F2201; engine oil pressure_{12-23-20}........1154
18F2202; engine oil level_{12-22-13}........1156
18F2202; engine oil level_{12-21-16}........1158
18F2203; engine oil temperature_{12-20-20}........1160
18F2203; engine oil temperature_{12-19-27}........1162
19F3701; bus communication reduced_{12-18-16}........1164
19F3701; bus communication reduced_{12-17-48}........1166
19F3702; bus communication open circuit_{12-17-10}........1167
19F3702; bus communication open circuit_{12-16-35}........1169
20F2501; pedal request engine brake_retarder_{12-15-51}........1171
20F2501; pedal request engine brake_retarder_{12-15-30}........1173
20F2502; request engine brake........1175
20F4201; transmission limitation brake torque application_{12-13-53}........1177
20F4201; transmission limitation brake torque application_{12-13-18}........1179
20F4202; retarder activation_{12-12-31}........1181
20F4202; retarder activation_{12-11-56}........1183
20F4202; retarder activation_{12-11-21}........1185
20F4202; retarder activation_{12-10-45}........1187
20F5201; brake lights_{12-10-01}........1189
20F5201; brake lights_{12-09-40}........1190
21F2701; engine On_Off_{12-09-02}........1191
21F2701; engine On_Off_{12-08-42}........1193
21F2701; engine On_Off_{12-08-21}........1195
21F2702; starter motor_{12-07-49}........1197
21F2702; starter motor_{12-07-28}........1199
21F2703; stop engine_{12-06-56}........1201
21F2703; stop engine_{12-06-35}........1202
21F3301; start electronics........1203
21F3302; stop electronics_{12-05-05}........1205
21F3302; stop electronics_{12-04-30}........1207
21F3303; software-controlled engine stop........1209
21F3304; safety stop........1210
22F8501; seat belt; check........1211
24F9901; theft protection_{12-01-54}........1213
25F9101 Warning; dump lever not in float position........1215
25F9102 Warning; dump lever not in hold position........1216
25F9501 Warning; body up........1218
25F9502; work cycle start........1220
26F3601; windshield washer........1221
26F3603; windshield wiper interval........1222
28F2701; engine speed........1223
28F2702; idle speed........1225
28F2703; engine speed monitoring_{11-56-24}........1226
28F2703; engine speed monitoring_{11-55-53}........1228
28F4301; vehicle speed_distance_{11-55-10}........1230
28F4301; vehicle speed_distance_{11-54-41}........1232
28F4301; vehicle speed_distance_{11-54-11}........1234
28F4301; vehicle speed_distance_{11-53-42}........1236
28F4302 Exceeded speed limit........1238
28F4201 transmission overspeeding........1239
29F4201; oil temperature; display........1241
29F4301; oil temperature dropbox........1242
30F4201; back-up alarm and back-up light........1244
30F4202; gearshift selector........1245
30F4203; shift lock-out (hold)........1247
30F4204; start 2nd gear........1249
31F3601; buzzer central warning........1250
31F3801; orange central warning........1251
31F3802; red central warning........1252
31F3803; red extra central warning........1253
31F3804; external activation of red central warning........1254
31F3805; external activation of orange central warning........1255
31F3806; external activation of buzzer central warning........1256
32F3807; information display unit; display outside temperature........1257
32F5201; Display unit; brake cooling oil temperature........1258
33F5202; Service display unit; brake cooling oil temperature in axles........1260
35F9901 Parameter list_{11-40-46}........1261
35F9901 Parameter list_{11-40-25}........1263
35F9901 Parameter list_{11-40-04}........1265
35F9901 Parameter list_{11-39-43}........1267
35F9901 Parameters; MO2 module transmission_{11-39-04}........1269
35F9901 Parameters; MO2 module transmission_{11-38-44}........1271
35F9901 Parameters; MO2 module transmission_{11-38-23}........1272
35F9901 Parameters; MO2 module transmission_{11-38-02}........1273
35F9901 Parameters; MO3 module acceleration........1274
35F9901 Parameters; MO4 module power take-off........1276
35F9901 Parameters; MO5 module wheel brakes........1277
35F9901 Parameters; MO6 module fuel........1278
35F9901 Parameters; MO8 module display setting........1279
35F9901 Parameters; MO9 module inlet system........1281
35F9901 Parameters; MO10 module oils; pressures_{11-35-25}........1282
35F9901 Parameters; MO10 module oils; pressures_{11-35-05}........1283
35F9901 Parameters; MO10 module oils; pressures_{11-34-44}........1284
35F9901 Parameters; MO14 module delayed stop........1285
35F9901 Parameters; MO18 module engine oil........1286
35F9901 Parameters; MO20 module retardation........1287
35F9901 Parameters; MO21 module start–stop_{11-33-09}........1288
35F9901 Parameters; MO21 module start–stop_{11-32-49}........1289
35F9901 Parameters; MO22 module operator's seat........1290
35F9901 Parameters; MO24 module theft protection........1291
35F9901 Parameters; MO25 module dump lever........1292
35F9901 Parameters; MO26 module wipers_washing windshield........1293
35F9901 Parameters; MO28 module speeds (rpm)_{11-30-45}........1294
35F9901 Parameters; MO28 module speeds (rpm)_{11-30-24}........1296
35F9901 Parameters; MO28 module speeds (rpm)_{11-30-03}........1298
35F9901 Parameters; MO30 module gear selector........1300
35F9901 Parameters; MO31 module warnings........1301
35F9901 Parameters; MO37 module service_{11-28-48}........1302
35F9901 Parameters; MO37 module service_{11-28-28}........1304
37F3801; service interval machine_{11-27-43}........1306
37F3801; service interval machine_{11-26-38}........1309
37F3801; service interval machine_{11-25-47}........1311
37F3802; service interval engine oil........1313
37F3803; service interval transmission oil........1315
38F4301; dropbox activation........1317
38F4302; dropbox indication H to L........1319
V2002.3.0; change specification........1321
V2002.4.0; change specification........1322
V2003.3.1; change specification........1323
V2003.4.1_V2003.4.2; change specification........1324
V2003.4.3_V2003.4.4; change specification........1325
V2003.6.0; change specification........1326
V2003.6.2; change specification........1327
V2004.4.0; change specification........1328
V2004.4.1; change specification........1329
V2004.6.0; change specification........1330
V2005.2.0; change specification........1331
V2005.3.0; change specification........1332
V2005.5.0; change specification........1333
V2005.6.0; change specification........1334
V2006.1.0; change specification........1335
V2006.3.1; change specification........1337
V2006.3.2; change specification........1338
V2006.3.3; change specification........1339
V2006.5.0; change specification........1340
V2006.6.0; change specification........1341
V2006.6.1; change specification........1342
V2007.1.0; change specification........1343
V2007.2.0; change specification........1344
V2007.3.0; change specification........1345
V2007.4.0; change specification........1346
Software design........1347
MO1; engine (EMS)........1350
MO2; transmission........1351
MO3; acceleration........1352
MO4; power take-off........1353
MO5; wheel brakes........1354
MO6; fuel........1355
MO7; differential lock........1356
MO8; display setting........1357
MO9; inlet system........1358
MO10; oils; pressure........1359
MO12; cooling system........1360
MO13; charging system........1361
MO14; delayed stop........1362
MO15; inclination........1363
MO17; machine hours and machine distance........1364
MO18; engine oil........1365
MO19; program........1366
MO20; retardation........1367
MO21; start–stop_{11-05-44}........1368
MO21; start–stop_{11-05-25}........1369
MO21; start–stop_{11-05-04}........1370
MO22; operator's seat........1371
MO24; theft protection........1372
MO25; dump lever........1373
MO26; wiper_washing windshield........1374
MO28; speed (rpm)........1375
MO29; oil; transmission........1376
MO30; gear selector........1377
MO31; warnings........1378
MO32; information display unit; display........1379
MO33; service display unit Contronic........1380
MO34; logs........1381
MO35; service socket interface_{11-00-45}........1382
MO35; service socket interface_{11-00-25}........1384
MO35; service socket interface_{11-00-05}........1386
MO36; components_error codes........1388
MO37; service........1389
MO38; dropbox........1390
Troubleshooting strategy-[5834]........1391
Troubleshooting strategy........1392
Troubleshooting; general........1394
Error codes; build-up........1395
SAE J1708 (Information bus)........1400
SAE J1939_ CAN-bus (control bus)........1402
Error detection-[5417]........1404
Error detection........1406
Error causes........1408
Error codes; showing........1412
Error code information; description........1414
SAE error code (VCADS Pro) list for component designation; general........1416
SAE code; conversion to component designation; T–ECU........1417
SAE code; conversion for component designation; E-ECU_{10-49-16}........1419
SAE code; conversion for component designation; E-ECU_{10-48-55}........1422
SAE code; conversion for component designation; E-ECU_{10-48-35}........1425
SAE code; conversion to component designation; C–ECU........1428
SAE code; conversion to component designation; V–ECU........1429
Electrical cabling and connectors; checking........1431
Measuring; general........1436
Measuring symbols; description........1438
Component descriptions........1442
Component troubleshooting; structure; description........1446
Component troubleshooting; checking wiring harness and input_output on ECU........1448
Component troubleshooting; checking component........1450
Component troubleshooting; checking subsystem (circuit)........1452
Electronic control system; special tool measuring; general........1454
Electronic control system; special tool measuring; E–ECU........1456
Electronic control system; special tool measuring; I-ECU........1458
Electronic control system; special tool measuring; C–; T– and V–ECU........1460
Electronic control system; special tool measuring; transmission PT........1461
Electronic control system; special tool measuring; component........1463
MID 128 PID 158 Battery voltage; description and measuring_{10-25-51}........1464
MID 128 PID 158 Battery voltage; description and measuring_{10-24-55}........1466
MID 128 PID 158 Battery voltage; description and measuring_{10-23-52}........1467
MID 128 PID 158 Battery voltage; description and measuring_{10-22-57}........1469
HE2501; description and measuring_{10-21-45}........1470
HE2501; description and measuring_{10-20-38}........1472
MA2301–MA2306; description and measuring_{10-17-20}........1474
MA2301–MA2306; description and measuring_{10-16-02}........1477
MA2502; description and measuring_{12-46-27}........1480
MA2502; description and measuring_{12-44-55}........1482
MA2503; description and measuring........1484
MA2504; description and measuring_{12-38-53}........1486
MA2504; description and measuring_{12-37-12}........1488
MA4201-MA4207; description and measuring........1490
MA4302–MA4304; description and measuring........1492
MA4601-MA4603; description and measuring_{12-31-28}........1494
MA4601-MA4603; description and measuring_{12-29-56}........1496
MA4604; description and measuring_{12-28-08}........1498
MA4604; description and measuring_{12-26-34}........1500
MA5201; description and measuring_{12-24-42}........1502
MA5201; description and measuring_{12-23-02}........1504
MA5501_MA5502; description and measuring_{12-20-57}........1506
MA5501_MA5502; description and measuring_{12-19-11}........1508
MA5901; description and measuring........1510
MA8701; description and measuring........1511
MA9101; description and measuring_{12-12-40}........1513
MA9101; description and measuring_{12-11-10}........1515
MA9102; description and measuring........1517
MA9101; description and measuring_{12-06-05}........1519
MA9101; description and measuring_{12-04-39}........1521
MID 128 SID 211 5 V feed to engine sensors 2; description and measuring........1523
MID 128 SID 230 IVS; description and measuring_{12-02-28}........1525
MID 128 SID 230 IVS; description and measuring_{12-01-43}........1527
MID 128 SID 232 5 V feed to engine sensors 1; description and measuring_{12-00-42}........1529
MID 128 SID 232 5 V feed to engine sensors 1; description and measuring_{12-00-19}........1531
PWM2501; description and measuring_{11-59-44}........1532
PWM2501; description and measuring_{11-58-32}........1534
PWM2601_PWM2602; description and measuring........1536
PWM4201; description and measuring........1538
PWM4202; description and measuring........1540
PWM4203; description and measuring........1542
PWM4204; description and measuring........1544
R3501_R3502; description and measuring........1546
RE2501; description and measuring_{11-46-05}........1548
RE2501; description and measuring_{11-45-05}........1550
RE3302; description and measuring........1552
RE3704; description and measuring_{11-41-50}........1554
RE3704; description and measuring_{11-40-39}........1556
RE3801; description and measuring........1558
RExxxx; Relays general; description and measuring........1559
SAE J1708_1587 information link; description and measuring........1561
SAE J1939_CAN control link; description and measuring........1563
SE2202; description and measuring_{11-33-09}........1565
SE2202; description and measuring_{11-31-36}........1567
SE2203; description and measuring_{11-29-46}........1569
SE2203; description and measuring_{11-28-08}........1571
SE2205; description and measuring_{11-26-16}........1573
SE2205; description and measuring_{11-25-10}........1575
SE2301; description and measuring_{11-23-37}........1577
SE2301; description and measuring_{11-21-59}........1579
SE2302; description and measuring_{11-20-09}........1581
SE2302; description and measuring_{11-19-05}........1583
SE2303; description and measuring_{11-17-28}........1585
SE2303; description and measuring_{11-15-56}........1587
SE2501; description and measuring_{11-14-03}........1589
SE2501; description and measuring_{11-12-28}........1591
SE2502; description and measuring_{11-10-45}........1593
SE2502; description and measuring_{11-09-14}........1595
SE2507; description and measuring_{11-07-31}........1597
SE2507; description and measuring_{11-06-02}........1599
SE2508; description and measuring_{11-04-24}........1601
SE2508; description and measuring_{11-02-43}........1603
SE2509; description and measuring_{11-00-42}........1605
SE2509; description and measuring_{10-59-17}........1607
SE2601_SE2602; description and measuring........1609
SE2603; description and measuring_{10-54-56}........1611
SE2603; description and measuring_{10-53-26}........1613
SE2606; description and measuring_{10-51-44}........1615
SE2606; description and measuring_{10-50-08}........1617
SE2701; description and measuring_{10-48-12}........1619
SE2701; description and measuring_{10-46-52}........1621
SE2702; description and measuring_{10-45-08}........1623
SE2702; description and measuring_{10-42-30}........1625
SE2703; description and measuring_{10-40-00}........1627
SE2703; description and measuring_{10-38-42}........1629
SE3201; description and measuring_{10-37-09}........1631
SE3201; description and measuring_{10-36-25}........1632
SE3501; description and measuring_{10-35-30}........1633
SE3501; description and measuring_{10-34-45}........1634
SE3601; description and measuring........1635
SE3602; description and measuring........1636
SE3801; description and measuring_{10-29-40}........1637
SE3801; description and measuring_{10-28-17}........1639
SE3802; description and measuring_{10-26-42}........1641
SE3802; description and measuring_{10-24-58}........1643
SE4201; description and measuring_{10-22-42}........1645
SE4201; description and measuring_{10-21-16}........1648
SE4202; description and measuring........1651
SE4203; description and measuring........1653
SE4204; description and measuring........1655
SE4208; description and measuring_{10-11-12}........1657
SE4208; description and measuring_{10-09-45}........1659
SE4307; description and measuring-[0753]........1661
SE4212; description and measuring........1663
SE4213; description and measuring........1665
SE4214; description and measuring........1667
SE4302; description and measuring_{09-59-04}........1669
SE4302; description and measuring_{09-57-32}........1671
SE4305; description and measuring_{09-55-39}........1673
SE4305; description and measuring_{09-53-51}........1675
SE4306; description and measuring_{09-50-50}........1677
SE4306; description and measuring_{09-48-57}........1679
SE4307; description and measuring........1681
SE4607; description and measuring_{09-44-31}........1683
SE4607; description and measuring_{09-43-11}........1685
SE5201_SE5202; description and measuring_{09-41-37}........1687
SE5201_SE5202; description and measuring_{09-40-15}........1689
SE5203_SE5204; description and measuring_{09-38-38}........1691
SE5203_SE5204; description and measuring_{09-37-13}........1693
SE5207; description and measuring_{09-35-42}........1695
SE5207; description and measuring_{09-34-17}........1697
SE5208–SE5213; description and measuring_{09-32-39}........1699
SE5208–SE5213; description and measuring_{09-31-07}........1701
SE5214; description and measuring_{09-29-14}........1703
SE5214; description and measuring_{09-28-08}........1705
SE5214; description and measuring_{09-27-06}........1706
SE5501; description and measuring........1708
SE5502; description and measuring........1710
SE8301; description and measuring_{09-21-48}........1712
SE8301; description and measuring_{09-20-34}........1714
SE8501; description and measuring_{09-19-10}........1716
SE8501; description and measuring_{09-17-56}........1718
SE8502; description and measuring_{09-16-21}........1720
SE8502; description and measuring_{09-14-57}........1722
SE8701; description and measuring........1724
SE8702; description and measuring........1726
SE9101; description and measuring........1728
SE9102_SE9103; description and measuring_{09-05-12}........1730
SE9102_SE9103; description and measuring_{09-03-51}........1732
SE9104; description and measuring_{09-02-15}........1734
SE9104; description and measuring_{09-01-10}........1736
SE9104; description and measuring_{09-00-05}........1738
SE9105; description and measuring_{08-58-20}........1740
SE9105; description and measuring_{08-56-56}........1742
SE9501; description and measuring........1744
SE4201; description and measuring_{08-53-21}........1746
SE4201; description and measuring_{08-52-02}........1749
SE4201; description and measuring_{08-50-31}........1752
SE4201; description and measuring_{08-49-08}........1755
SWxxxx; description and measuring........1758
SW3301; description and measuring_{08-44-42}........1760
SW3301; description and measuring_{08-43-22}........1762
SW3602; description and measuring_{08-41-27}........1764
SW3602; description and measuring_{08-40-11}........1766
SW3608; description and measuring_{08-38-39}........1768
SW3608; description and measuring_{08-37-25}........1770
SW3801; description and measuring........1772
SW5501; description and measuring_{08-34-26}........1774
SW5501; description and measuring_{08-33-40}........1776
Error codes; Tech Tool........1778
C-ECU; error codes-[3226]........1780
D-ECU; error codes-[3152]........1782
E-ECU; error codes-[3125]........1784
T-ECU; error codes-[3051]........1786
V-ECU; error codes-[3000]........1788
C-ECU; error codes........1790
D-ECU; error codes........1792
E-ECU; error codes........1794
T-ECU; error codes........1796
V-ECU; error codes........1798
MID 128 PID 84 Machine travel speed; error codes........1800
MID 128 PID 91 Accelerator pedal position; error codes........1802
MID 128 PID 108 Sensor atmospheric pressure; error codes........1804
MID 128 PID 158 Battery voltage; error codes_{08-25-54}........1806
MID 128 PID 158 Battery voltage; error codes_{08-25-35}........1808
MID 128 PPID 55 Temperature ECU; error codes........1810
MID 128 PPID 86 Engine retarder (); error codes........1812
MID 128 SID 211 5 V feed to engine sensors 2; error codes........1814
MID 128 SID 230 IVS; error codes_{08-23-54}........1816
MID 128 SID 230 IVS; error codes_{08-23-35}........1818
MID 128 SID 231 SAE J1939_CAN control link; error codes........1820
MID 128 SID 232 5 V feed to engine sensors 1; error codes_{08-22-44}........1822
MID 128 SID 232 5 V feed to engine sensors 1; error codes_{08-22-24}........1824
MID 128 SID 240 Programme memory (Flash); error codes........1826
MID 128 SID 250 SAE J1708_1587 Information link; error codes........1828
MID 128 SID 253 Data set memory (EEPROM); error codes........1829
MID 128 SID 254 Engine control unit; error codes_{08-20-55}........1831
MID 128 SID 254 Engine control unit; error codes_{08-20-36}........1833
HE2501; error codes_{08-20-05}........1835
HE2501; error codes_{08-19-43}........1838
MA2301; error codes_{08-19-08}........1840
MA2301; error codes_{08-18-42}........1844
MA2302; error codes_{08-18-03}........1848
MA2302; error codes_{08-17-36}........1852
MA2303; error codes_{08-16-58}........1856
MA2303; error codes_{08-16-32}........1860
MA2304; error codes_{08-15-53}........1864
MA2304; error codes_{08-15-27}........1868
MA2305; error codes_{08-14-48}........1872
MA2305; error codes_{08-14-22}........1876
MA2306; error codes_{08-13-43}........1880
MA2306; error codes_{08-13-17}........1884
PWM2501; error codes_{08-12-33}........1888
PWM2501; error codes_{08-12-04}........1891
MA2502; error codes_{08-11-30}........1893
MA2502; error codes_{08-11-08}........1895
MA2503; error codes........1897
MA2504; error codes........1899
MA4201; error codes........1902
MA4202; error codes........1904
MA4203; error codes........1906
MA4204; error codes........1908
MA4205; error codes........1910
MA4206; error codes........1912
MA4207; error codes........1914
MA4302; error codes........1916
MA4303; error codes........1918
MA4304; error codes........1920
MA4601; error codes_{08-04-17}........1922
MA4601; error codes_{08-03-54}........1924
MA4602; error codes_{08-03-20}........1926
MA4602; error codes_{08-02-57}........1928
MA4603; error codes_{08-02-23}........1930
MA4603; error codes_{08-02-00}........1932
MA4604; error codes_{08-01-26}........1934
MA4604; error codes_{08-01-04}........1936
MA5201; error codes_{08-00-30}........1938
MA5201; error codes_{08-00-04}........1940
MA5501; error codes........1942
MA5502; error codes_{07-58-59}........1944
MA5502; error codes_{07-58-36}........1946
MA5901; error codes........1948
MA9101; error codes_{07-57-21}........1950
MA9101; error codes_{07-56-58}........1952
MA9102; error codes........1954
PWM2601; error codes........1956
PWM2602; error codes........1958
PWM4201; error codes........1960
PWM4202; error codes........1962
PWM4203; error codes........1964
PWM4204; error codes........1966
RE2501; error codes_{07-52-33}........1968
RE2501; error codes_{07-52-07}........1971
RE3301; error codes_{07-51-29}........1973
RE3301; error codes_{07-50-52}........1975
RE3601; error codes_{07-50-18}........1977
RE3601; error codes_{07-49-55}........1979
RE3602; error codes_{07-49-21}........1981
RE3602; error codes_{07-48-58}........1983
RE3603; error codes_{07-48-24}........1985
RE3603; error codes_{07-48-01}........1987
RE3801; error codes........1989
RE4201; error codes........1991
RE5201; error codes........1993
SE2202; error codes_{07-45-56}........1995
SE2202; error codes_{07-45-30}........1997
SE2203; error codes_{07-44-56}........1999
SE2203; error codes_{07-44-34}........2001
SE2205; error codes_{07-44-00}........2003
SE2205; error codes_{07-43-37}........2005
SE2301; error codes_{07-43-00}........2007
SE2301; error codes_{07-42-36}........2009
SE2302; error codes_{07-41-59}........2011
SE2302; error codes_{07-41-37}........2013
SE2303; error codes_{07-41-03}........2015
SE2303; error codes_{07-40-40}........2017
SE2501; error codes_{07-40-00}........2019
SE2501; error codes_{07-39-38}........2021
SE2502; error codes_{07-39-04}........2023
SE2502; error codes_{07-38-39}........2025
SE2507; error codes_{07-38-04}........2027
SE2507; error codes_{07-37-42}........2029
SE2508; error codes_{07-37-08}........2031
SE2508; error codes_{07-36-46}........2033
SE2509; error codes........2035
SE2601; error codes........2037
SE2602; error codes........2039
SE2603; error codes_{07-34-29}........2041
SE2603; error codes_{07-34-06}........2043
SE2606; error codes_{07-33-32}........2045
SE2606; error codes_{07-33-10}........2047
SE2701; error codes........2049
SE2702; error codes_{07-32-03}........2051
SE2702; error codes_{07-31-41}........2054
SE2703; error codes_{07-31-07}........2057
SE2703; error codes_{07-30-45}........2060
SE3801; error codes_{07-30-11}........2062
SE3801; error codes_{07-29-48}........2064
SE3802; error codes_{07-29-14}........2066
SE3802; error codes_{07-28-51}........2068
SE4201; error codes_{07-28-17}........2070
SE4201; error codes_{07-27-54}........2072
SE4202; error codes........2074
SE4203; error codes........2076
SE4204; error codes........2078
SE4208; error codes_{07-25-45}........2080
SE4208; error codes_{07-25-23}........2082
SE4212; error codes........2084
SE4213; error codes........2086
SE4214; error codes........2088
SE4302; error codes_{07-23-07}........2090
SE4302; error codes_{07-22-44}........2092
SE4307; error codes........2094
SE5201; error codes_{07-21-35}........2096
SE5201; error codes_{07-21-13}........2098
SE5202; error codes_{07-20-39}........2100
SE5202; error codes_{07-20-17}........2102
SE5203; error codes_{07-19-43}........2104
SE5203; error codes_{07-19-21}........2106
SE5204; error codes_{07-18-47}........2108
SE5204; error codes_{07-18-24}........2110
SE5207; error codes_{07-17-42}........2112
SE5207; error codes_{07-17-19}........2114
SE5208; error codes_{07-16-45}........2116
SE5208; error codes_{07-16-23}........2118
SE5209; error codes_{07-15-49}........2120
SE5209; error codes_{07-15-26}........2122
SE5210; error codes_{07-14-52}........2124
SE5210; error codes_{07-14-30}........2126
SE5211; error codes_{07-13-55}........2128
SE5211; error codes_{07-13-33}........2130
SE5212; error codes_{07-13-00}........2132
SE5212; error codes_{07-12-37}........2134
SE5213; error codes_{07-11-49}........2136
SE5213; error codes_{07-11-27}........2138
SE5214; error codes........2140
SE5501; error codes........2142
SE5502; error codes........2144
SE9102; error codes_{07-09-36}........2145
SE9102; error codes_{07-09-14}........2147
SE9103; error codes_{07-08-40}........2149
SE9103; error codes_{07-08-18}........2151
SE9104; error codes........2153
SE9105; error codes........2155
SW2705; error codes........2157
SW3301; error codes_{07-06-07}........2158
SW3301; error codes_{07-05-45}........2160
SW5501; error codes_{07-05-10}........2162
SW5501; error codes_{07-04-48}........2163
SW5501; error codes_{07-04-26}........2164
31 - BATTERY........2165
Battery; description........2166
Battery; specifications........2167
Battery; charging........2168
Batteries; replacing........2170
32 - ALTERNATOR; CHARGE REGULATOR........2177
Alternator; specifications_{07-00-27}........2178
Alternator; specifications_{07-00-08}........2180
Alternator; tightening torques........2181
Alternator; description........2183
Alternator; replacing incl function checking_{06-58-59}........2184
Alternator; changing_{06-58-37}........2187
33 - STARTING SYSTEM........2194
Starter motor; specification_{06-57-44}........2195
Starter motor; specification_{06-57-25}........2197
Starter motor; tightening torques........2198
Starter motor; replacing........2200
Cold-start device; specifications........2207
35 - LIGHTING........2208
Lighting; specifications........2209
Headlamp; high and low beams; adjusting........2211
Headlamp; high beam; replacing........2214
Headlamp; low beam; replacing........2219
36 - OTHER ELECTRICAL EQUIPMENT........2225
General instructions for controls; replacing........2226
Gearshift selector; changing........2229
Parking brake lever; changing........2235
Combined control by steering wheel; changing........2239
Dump lever; changing........2247
Electric hood pump; changing........2252
Windscreen wiper motor; tightening torques........2256
Windscreen wiper front motor; replacing........2257
4-pin DIN-connectors; remounting........2270
Connectors C01–DY; position........2272
Connectors EA–F50; position........2275
Connectors HE3601–TAILR; position........2278
Connectors; overview........2281
C-ECU; MID178; changing non-programmed ECU........2288
C-ECU; MID178; changing pre-programmed ECU........2294
I-ECU MID 140 non-programmed; replacing........2295
I-ECU MID 140 pre-programmed; replacing........2299
T-ECU; MID 130; changing non-programmed ECU........2300
T-ECU; MID 130; changing pre-programmed ECU........2306
V-ECU MID 187 non-programmed; replacing_{06-37-12}........2307
V-ECU MID 187 non-programmed; replacing_{06-36-31}........2317
V-ECU MID 187 pre-programmed; replacing_{06-35-28}........2330
V-ECU MID 187 pre-programmed; replacing_{06-35-09}........2332
Tech Tool; programming of machine........2333
37 - CABLE; FUSE; RELAY........2335
Electrical symbols and designations........2339
Explanation of wiring diagrams........2343
Wiring diagrams........2346
Wiring diagram A01_{06-30-46}........2348
Wiring diagram A01_{06-30-24}........2351
Wiring diagram A01_{06-30-02}........2354
Wiring diagram A01_{06-29-39}........2357
Wiring diagram A02_{06-29-05}........2360
Wiring diagram A02_{06-28-43}........2362
Wiring diagram A03_{06-28-09}........2364
Wiring diagram A03_{06-27-46}........2367
Wiring diagram A03_{06-27-24}........2369
Wiring diagram A04_{06-26-50}........2371
Wiring diagram A04_{06-26-28}........2374
Wiring diagram A04_{06-26-05}........2377
Wiring diagram A04_{06-25-43}........2380
Wiring diagram A05_{06-25-03}........2383
Wiring diagram A05_{06-24-40}........2386
Wiring diagram A05_{06-24-18}........2389
Wiring diagram A06_{06-23-35}........2393
Wiring diagram A06_{06-23-13}........2396
Wiring diagram A07_{06-22-39}........2399
Wiring diagram A07_{06-22-16}........2402
Wiring diagram A07_{06-21-54}........2405
Wiring diagram A08_{06-21-08}........2408
Wiring diagram A08_{06-20-46}........2411
Wiring diagram A08_{06-20-23}........2414
Wiring diagram A09_{06-19-49}........2417
Wiring diagram A09_{06-19-27}........2420
Wiring diagram A09_{06-19-04}........2423
Wiring diagram A10_{06-18-30}........2427
Wiring diagram A10_{06-18-08}........2430
Wiring diagram A10_{06-17-46}........2433
Wiring diagram A11_{06-17-12}........2436
Wiring diagram A11_{06-16-50}........2439
Wiring diagram A11_{06-16-28}........2442
Wiring diagram A11_{06-16-05}........2445
Wiring diagram A12_{06-15-32}........2448
Wiring diagram A12_{06-15-10}........2451
Wiring diagram A12_{06-14-47}........2454
Wiring diagram A12_{06-14-25}........2457
Wiring diagram A13........2460
Wiring diagram A14_{06-13-19}........2463
Wiring diagram A14_{06-12-57}........2466
Wiring diagram A14_{06-12-34}........2469
Wiring diagram A15_{06-12-01}........2472
Wiring diagram A15_{06-11-38}........2475
Wiring diagram A15_{06-11-16}........2478
Wiring diagram A16_{06-10-42}........2481
Wiring diagram A16_{06-10-19}........2484
Wiring diagram A16_{06-09-57}........2487
Wiring diagram A17_{06-09-16}........2490
Wiring diagram A17_{06-08-54}........2493
Wiring diagram A17_{06-08-31}........2496
Wiring diagram A17_{06-08-09}........2499
Wiring diagram A18_{06-07-23}........2502
Wiring diagram A18_{06-07-01}........2505
Wiring diagram A18_{06-06-39}........2508
Wiring diagram A18_{06-06-16}........2511
Wiring diagram A19_{06-05-37}........2514
Wiring diagram A19_{06-05-14}........2517
Wiring diagram A19_{06-04-52}........2520
Wiring diagram A19_{06-04-30}........2523
Wiring diagram A20_{06-03-56}........2526
Wiring diagram A20_{06-03-34}........2529
Wiring diagram A20_{06-03-12}........2532
Wiring diagram A21_{06-02-38}........2535
Wiring diagram A21_{06-02-16}........2538
Wiring diagram A21_{06-01-53}........2541
Wiring diagram A22_{06-01-20}........2543
Wiring diagram A22_{06-00-57}........2546
Wiring diagram A22_{06-00-35}........2549
Wiring diagram A22_{06-00-12}........2552
Wiring diagram A23_{05-59-38}........2555
Wiring diagram A23_{05-59-16}........2558
Wiring diagram A23_{05-58-54}........2561
Wiring diagram A24_{05-58-14}........2564
Wiring diagram A24_{05-57-51}........2567
Wiring diagram A24_{05-57-29}........2570
Wiring diagram A24_{05-57-06}........2573
Wiring diagram A25_{05-56-32}........2576
Wiring diagram A25_{05-56-10}........2579
Wiring diagram A25_{05-55-48}........2582
Wiring diagram A26_{05-55-14}........2585
Wiring diagram A26_{05-54-52}........2588
Wiring diagram A27_{05-54-06}........2590
Wiring diagram A27_{05-53-43}........2593
Wiring diagram A28_{05-53-10}........2596
Wiring diagram A28_{05-52-48}........2599
Wiring diagram A33........2601
Electrical distribution box; description_{05-51-48}........2603
Electrical distribution box; description_{05-51-25}........2607
Other fuses and relays; description........2612
Grounding points; frame connections........2615
Component position 1; AL3201–HE8501........2617
Component position 2; IA–LA3601........2620
Component position 3; LA3602–LC4202........2623
Component position 4; LC4601–MA4207........2626
Component position 5; MA4302–PWM4204........2629
Component position 6; R3501–SA4201........2632
Component position 7; SE2202–SE5202........2635
Component position 8; SE5203–SO3901........2639
Component position 9; SW2502–SW4215........2642
Component position 10; SW4301–SW9102........2645
Components; list and positions........2648
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM........2649
Instruments and controls; overview........2651
Instruments and controls; left instrument panel........2653
Instruments and controls; main instrument........2655
Instruments and controls; right instrument panel........2658
Instruments and controls; climate control panel........2661
Description; components........2662
Display unit; content........2663
Information display unit; general........2665
Information; build-up........2666
Display unit and keyboard........2667
Key functions........2669
Theft protection........2671
Start electronics........2673
Stop electronics........2675
Menu tree........2677
Group 0; setup screens........2681
0.0 Setting screen alternative........2684
0.2 Setting units........2686
0.3 Setting time........2688
0.4 Setting date........2690
Group 1; service screens........2692
1.0 Setting to zero; service interval machine........2695
1.0.1 Engine oil; monitoring change interval........2697
1.0.1 Acknowledgement; change of engine oil........2699
1.0.2 Transmission oil; monitoring change interval........2701
1.0.2 Acknowledgement; change of transmission oil........2703
1.1_ 1.2 Error code screens; general........2705
1.1_ 1.2 Error code screens; engine........2707
1.1_ 1.2 Error code screens; electrical system........2709
1.1_ 1.2 Error code screens; power transmission........2711
1.1_ 1.2 Error code screens; brakes........2713
1.1_ 1.2 Error code screens; hydraulics........2715
1.3_1.4 Saved error codes_warnings........2716
1.3_1.4 Setting to zero; saved error codes_warnings........2718
Group 2; screens; engine........2720
2.4 Setting; raised engine speed........2723
Group 3; screens; electrical system........2725
Group 4; screens; transmission........2726
Group 5; screens axles_brakes........2728
Group 8; screens Operating Information........2729
Group 9; hydraulic screens........2732
Warning screens; general........2733
Warning screens; engine........2736
Warning screens; electrical system........2741
Warning screens; power transmission........2745
Warning screens; axles_brakes........2749
Warning screens; cab........2752
Warning screens; hydraulic system........2754
Service display unit; general........2757
Initial display and settings........2759
Operating information and service........2763
Engine........2766
Electrical system........2769
Transmission........2774
Axles and brakes........2779
Hydraulics........2781
Digital input and output signals........2783
Service display unit; summary........2794
39 - MISCELLANEOUS........2796
Rear view monitor; service menu........2797
CareTrack system; description........2802
CareTrack antenna; replacing........2804
004 - POWER TRANSMISSION........2812
40 - GENERAL........2813
Section 004; content; structure........2814
Power transmission; specifications........2816
Transmission; capacities-........2817
Dropbox; capacities........2818
Drive axles; capacity........2819
Drivetrain; description........2820
41 - CLUTCH; TORQUE CONVERTER........2822
Description ........2823
Lock-up clutch........2825
42 - TRANSMISSION; HYDRAULIC CONTROL........2826
Hydraulic diagram PT - Image........2827
Transmission; specifications........2828
Transmission oil pressure; specifications........2830
Transmission; capacities........2833
Hydraulic transmission; weight........2834
Transmission of power........2835
Planetary gear........2837
Description-........2839
Transmission; clutches and brakes........2841
Gear F1........2843
Gear F2........2844
Gear F3........2845
Gear F4........2846
Gear F5........2847
Gear F6........2848
Reverse gear R1........2850
Reverse gear R2........2852
Description; retarder........2853
Pressure accumulation........2855
Component and description........2857
Hydraulic diagram PT-........2861
Transmission; removing downward........2864
Transmission; installing from underneath........2878
Transmission; removing upward........2889
Transmission; installing from above........2903
Transmission; removing from a non mounted engine........2916
Transmission; installing on a non mounted engine........2920
Seal for rear output shaft; replacing........2923
Induction sensor for turbine speed; replacing........2931
Checking of main; torque converter and lubricating oil pressure........2936
44 - HYDROSTATIC DRIVE........2939
Dropbox; general........2940
Dropbox; specifications........2954
Dropbox; weights FL 992_ FL 1002_{04-51-13}........2955
Dropbox; weights FL 852_ FL 862_{04-50-54}........2956
Dropbox; removing........2957
Dropbox; mounting........2964
Position monitor high_low range; adjusting........2970
Front output shaft on dropbox; changing seal........2975
Rear output shaft on dropbox; changing seal........2979
Input shaft on dropbox; changing seal........2984
45 - PROPELLER SHAFT........2987
Propeller shaft........2988
Intermediate shaft; cut-away view........2989
Propeller shaft; tightening torque........2991
Intermediate shaft and_or bearing; changing........2993
46 - FRONT AXLE; REAR AXLE........3020
Drive axles A40D........3021
Description........3022
Front axle_rear axle; weights........3023
Output shaft 6-wheel drive; changing bearing........3024
Dog-clutch for six-wheel drive (6x6); checking and adjusting........3038
Differential carrier assembly; replacing........3042
Transverse differential lock_axle; checking and adjusting........3054
Longitudinal differential lock; checking and adjusting - from underneath........3058
48 - POWER TAKE OFF........3061
Power take-off; tightening torque........3062
Power take-off; between engine and gearbox; reconditioning........3064
49 - MISCELLANEOUS........3100
Hydraulic diagram PT - Image........3101
Power take-off; between engine and gearbox; reconditioning........3102
Hydraulic diagram PT........3117
Transmission PT1860; cut-away........3120
Transmission PT1862; cut-away view........3122
Oil cooler; tightening torques........3124
Oil cooler; replacing........3126
005 - BRAKE........3130
50 - GENERAL........3131
Axles; designations........3132
Brakes; specification; A40D (AHW71L–AHW71N; AHW71O–AHW71Q)........3133
Brake system; specifications........3135
Accumulator; specification........3137
Compressed-air system; specifications........3139
Brake cooling system; specification........3141
Brake oil pump; specifications........3142
Oils and seals AHW71L – AHW71N........3143
Oils and seals AHW71O – AHW71Q........3145
Hub end; cross-section AHW71L – AHW71N........3148
Hub end; cross-section AHW71O – AHW71Q........3151
Compressed air system; description........3155
Pressure check connections; description-[1528]........3157
Hydraulic diagram; brake system; wet brakes_{01-14-59}........3158
Hydraulic diagram; brake system; wet brakes_{01-14-37}........3162
Compressed air diagram_{01-14-03}........3166
Compressed air diagram_{01-13-41}........3170
Compressed air diagram_{01-13-19}........3174
51 - WHEEL BRAKE........3178
Brake piston and wear indicator; basic setting........3179
52 - HYDRAULIC BRAKE SYSTEM........3184
Brake cooling oil system; diagram - Image........3185
Hydraulic brake system; pressure build-up........3187
Brake system; bleeding_{01-11-02}........3188
Brake system; bleeding_{01-10-36}........3193
Brake system; pressure releasing........3199
Brake system hydraulic function; checking........3201
Pressure check connections; description........3206
Brake cooling oil system; description........3207
Brake cooling oil system; diagram_{01-07-44}........3208
Brake cooling oil system; diagram_{01-07-22}........3211
Foot brake valve; description........3214
Foot brake valve; replacing........3216
Accumulator; checking........3220
Hydraulic pump; max working pressure; checking and adjusting........3223
Hydraulic pump; replacing........3227
Accumulator; discarding........3228
55 - PARKING BRAKE........3231
Parking brake; description........3232
Parking brake; function description........3233
Parking brake; specifications........3236
Parking brake; tightening torque........3237
Parking brake; replacing brake disc........3239
Parking brake brake pads; replacing........3248
Parking brake function; checking........3256
Load and dump brake; checking and adjusting working pressure........3258
56 - COMPRESSED-AIR BRAKE........3260
Compressor; replacing........3261
59 - MISCELLANEOUS........3272
Description........3273
006 - STEERING........3274
60 - GENERAL........3275
Steering system; description........3276
Troubleshooting tips-........3278
Steering system; specifications........3280
64 - STEERING........3281
Pressure build-up; engine-dependent pumps; description........3282
Steering gear; specifications........3285
Steering gear; checking and adjusting........3287
Steering gear; replacing........3291
Steering linkage; checking and adjusting_{12-50-09}........3300
Steering linkage; checking and adjusting_{12-49-47}........3302
Steering linkage; checking and adjusting........3309
Steering times; checking and adjusting........3314
Steering valve neutral position; checking and adjusting........3316
Steering cylinder; specifications........3320
Steering cylinder; description........3321
Steering cylinder; replacing........3326
Steering cylinder; removed; reconditioning........3337
Steering cylinder; reconditioning on machine........3348
Steering cylinder; replacing bearing; left-hand side........3361
Damping cylinder; specification........3372
Damping cylinder........3373
Damping cylinder; checking pre-load........3375
Damping cylinder seal; changing........3378
Secondary steering hydraulic pump; replacing........3383
Secondary steering; checking and adjusting max. pressure and stand-by pressure........3387
007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT........3392
71 - FRAME........3393
Tractor unit frame........3394
Load unit frame........3396
Front underbody skid plate; removing........3398
Front underbody skid plate; mounting........3400
72 - SUSPENSION........3402
Suspension; description........3403
74 - FRAME LINK........3405
Hitch; specifications........3406
Hitch; tightening torque........3409
Steering joint bearing........3411
Frame joint; separating the machine........3414
Steering joint spherical bearings; checking clearance........3434
Steering joint bearing; replacing........3436
75 - AXLE SUSPENSION........3454
Front axle........3455
Bogie member; replacing one rubber element........3456
Bogie member; replacing incl. Bearing; replacing........3460
77 - WHEELS; TRACKS; TYRE; HUB; DRUM........3471
Wheel; tightening torque........3472
Wheel; removing and fitting one........3474
Wheel; aligning........3476
008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE........3480
80 - GENERAL........3481
Cabin; specification........3482
Cab description........3483
81 - CAB; NAKED; CANOPY........3484
Instructions for drilling in ROPS structure........3485
Cab; removing........3489
Cab; installing........3504
Cab; lifting points........3515
82 - ENGINE HOOD; MUDGUARD; FOOT STEP........3518
Hydraulic diagram; hood opening........3519
Engine hood; removing........3521
Engine hood; installing........3524
Electric hood pump; changing........3527
83 - DOORS; HATCH; COVER PLATE; (all)........3531
Door; replacing........3532
Cab door; removing door catch........3535
Cab door; installing door catch........3538
Door lock; replacing........3540
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING........3544
Windows; general........3545
Windscreen; replacing........3547
Rear window pane; replacing........3555
Side window; replacing........3561
Door window; replacing........3565
85 - CAB INTERIOR; UPHOLSTERY........3570
Mechanical operator's seat; adjusting........3571
Air suspension operator's seat; adjusting_{12-07-17}........3573
Air suspension operator's seat; adjusting_{12-06-54}........3575
Operator's seat; changing air spring_{12-06-21}........3577
General maintenance instructions_{12-05-56}........3584
Operator's seat; removing_{12-05-26}........3586
Operator's seat; removing_{12-05-07}........3587
Operator's seat; installing........3590
86 - PROTECTIVE EQUIPMENT........3591
Protection against electromagnetic interference........3592
87 - AIR CONDITIONING UNIT........3594
Pressurizing with nitrogen gas........3595
Heater core; replacing........3597
Fan motor; replacing........3610
Heat control valve; replacing........3614
Heat control; replacing........3618
Thermostat; replacing........3620
Personal competence and accreditation........3623
Safety when working with air-conditioning refrigerant........3625
Repair instructions........3627
Air conditioning AC; basic principles........3629
Air conditioning unit; operation........3631
AC system; specifications........3634
Wiring diagram A23........3636
Refrigerant; filling incl vacuum pumping........3639
Checking for leaks with inspection light........3640
Cooling unit; performance test........3642
Evaporator; replacing incl draining and filling........3644
Receiver; replacing incl draining and filling........3654
Troubleshooting; air conditioning unit (AC)........3658
009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS........3660
90 - GENERAL........3661
Hydraulic diagram; complete - Image........3662
Explanations to hydraulic diagram........3664
Hydraulic components; cleanliness when handling........3673
Hydraulic diagram; complete_{11-44-09}........3676
Hydraulic diagram; complete_{11-43-47}........3680
Software; description........3685
Hydraulic and servo systems; description........3686
Hydraulic oil; description........3687
Hydraulic oil; storing and handling........3689
Hydraulic system; repair of hydraulic components in workshop........3691
Hydraulic components; storing and transporting........3693
Troubleshooting tips........3695
Hydraulic system; bleeding air; version 1........3697
Hydraulic system; bleeding air; version 2........3699
Vacuum pump; connection........3701
Vacuum pump; disconnection........3704
Hydraulic system; relieve pressure........3705
Hydraulic system; description........3706
BYD Yuan PLUS ........3709
Accumulator; discarding........3712
91 - WORKING HYDRAULIC; SERVO HYDRAULICS........3715
Hydraulic system; work instructions........3716
Pressure check connections; description........3718
Hydraulic tank; description........3720
Hydraulic system; capacities........3722
Steering and dumping valve; specifications........3723
Steering and dumping valve; tightening torques........3725
Steering and dumping valve; description_{11-35-16}........3727
Steering and dumping valve; description_{11-34-54}........3731
Non-return valve function in steering and dumping valve_{11-34-08}........3735
Non-return valve function in steering and dumping valve_{11-33-50}........3736
Steering and dumping valve; changing........3737
Steering and tipping valve; removing........3749
Steering and tipping valve; installing........3758
Steering and dumping valve; removed; reconditioning_{11-31-05}........3767
Steering and dumping valve; removed; reconditioning_{11-30-24}........3786
Dump lever; changing........3815
Hydraulic pumps; specifications_{11-28-42}........3820
Hydraulic pumps; specifications_{11-28-24}........3823
Hydraulic pump; description........3826
Working pumps; checking........3829
Hydraulic pump; standby pressure; checking and adjusting........3831
Hydraulic pump; max working pressure; checking and adjusting........3836
Pump regulator; checking........3840
Hydraulic pump; replacing_{11-25-45}........3844
Hydraulic pump; replacing_{11-25-23}........3848
Hydraulic pump (removed); changing shaft seal........3853
Shut-off P1 at low engine rpm (MA9102); checking function........3856
Dump lever; specifications........3857
Dump lever; description........3858
Dumping lever; checking pressure........3862
95 - LOAD CARRIER........3866
Dumping system; specification........3867
Hoist cylinder; specification........3868
Hoist cylinder; description........3869
Hoist cylinder; removing........3871
Hoist cylinder; installing........3875
Hoist cylinder bearing; changing_{10-55-32}........3879
Hoist cylinder bearing; changing_{10-55-10}........3885
Hoist cylinder removed; reconditioning........3890
Dump body; adjusting against frame........3899
Dump body joint; changing tipping bearing........3906
Body angle sensor; adjusting........3913
Cylinder; rear flap; gas pressure; checking and adjusting........3914
Dump body alternative; lowering........3918
99 - MISCELLANEOUS........3921
Hydraulic pressure; specifications........3922
Steering and dumping valve; overview illustration........3924
Foreword........3928
Articulated Haulers A40D Volvo Service Repair Manual
