Volvo A40D Service Repair Manual

Data Size: 65.29 MB 
File Type: PDF 
Language: English 
Manufacturer: Volvo 
Applicable Machine: Dump Truck 
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram 
Machine Model: Volvo A40D Dump Truck 
Page: 4423 Pages

List Contents:

0 Volvo A40D 
0.0 Setting screen alternative 
0.2 Setting units 
0.3 Setting time 
0.4 Setting date

0 1.0 Setting to zero, service interval machine 1.0.1 Acknowledgement, change of engine oil 1.0.1 Engine oil, monitoring change interval 1.0.2 Acknowledgement, change of transmission oil 1.0.2 Transmission oil, monitoring change interval 1.0 1.1- 1.2 Error code screens, electrical system 1.1- 1.2 Error code screens, engine 1.1- 1.2 Error code screens, general 1.1 1 1.1-1 1 2.4 Setting, raised engine speed 4-pin DIN-connectors, remounting 88830051 User Instruction AC system, specifications AC, time relay Accumulator, checking (2) Accumulator, checking Accumulator, discarding Accumulator, specification Action for reducing risk of fire Action to be taken in case of abnormal lubricating oil consumption Adjusting, general (2) Adjusting, general Air cleaner, description (2) Air cleaner, description Air cleaner, preheating coil, specifications Air conditioning AC, basic principles Air conditioning unit, operation (2) Air conditioning unit, operation Air conditioning, checking function Air in fuel system, checking Air intake and filter Air suspension operator's seat, adjusting (2) Air suspension operator's seat, adjusting (later version) 1 Air suspension operator's seat, adjusting (later version) Air suspension operator's seat, adjusting 1 Air suspension operator's seat, adjusting Air suspension operator's seat, adjusting 1 Air suspension operator's seat, adjusting 2 Air vent pipe, hydraulic tank Altered wind shield washer tank installation, improved self bleeding Alternative lubricants for axles with wet brakes Alternator, changing (2) Alternator, changing Alternator, description (2) Alternator, description Alternator, replacing incl function check Alternator, specifications Alternator, tightening torques Appointment and distribution of responsibility A-stay, new rubber bushing Automatic transmission lubricants 1 Automatic transmission lubricants Auxiliary steering, replacing hydraulic pump (2) Auxiliary steering, replacing hydraulic pump Axle housing, seal Axles and brakes screens Axles and brakes Axles, designations Axles 6-wheel drive, basic setting 6-wheel drive, reconditioning Differential, mounting 2 Differential, mounting Differential, mounting3 Differential, reconditioning 2 Differential, reconditioning 1 Final drive AH64J, AH64L, AHW71L, AHW71N, AHW71O, AHW71Q, reconditioning Final drive AH64K, AHW71M, AHW71P, reconditioning Final drive, mounting 1 Final drive, mounting Hub end AH64J-AH64L, reconditioning Hub end AHW71L-AHW71N, reconditioning Hub end AHW71O-AHW71Q, reconditioning Hub reduction AH64J-AH64L, reconditioning Hub reduction AHW71L-AHW71Q, reconditioning Intermediate shaft, reconditioning Marking pattern, pinion - crown wheel Output shaft 6-wheel drive, reconditioning Pinion, calculation of axial position Pinion, mounting Pinion, reconditioning 1 Pinion, reconditioning Power divider, assembling Power divider, mounting Power divider, reconditioning Transverse differential lock, reconditioning Transverse differential, adjusting Wheel hub AH64J-AH64L, reconditioning Wheel hub AHW71L-AHW71N, reconditioning Wheel hub AHW71O-AHW71Q, reconditioning Basic check, transmission Basic checks Batteries, replacing Batteries, service life Battery, changing Battery, charging (2) Battery, charging Battery, description (2) Battery, description Battery, specifications Bearing, output shaft, 1st bogie Belt guard, new type Bogie member, replacing incl. Bearing, replacing Bogie member, replacing one rubber element (2) Bogie member, replacing one rubber element Brake cooling oil system, description (2) Brake cooling oil system, description Brake cooling oil system, diagram (2) Brake cooling oil system, diagram Brake cooling oil system, diagram 1 Brake cooling oil system, diagram 2 Brake cooling oil, altered interval between changes Brake cooling system, specification Brake disc, changing Brake oil pump, specifications Brake piston and wear indicator AHW71L-AHW71N, basic setting 1 Brake piston and wear indicator AHW71L-AHW71N, basic setting Brake piston and wear indicator AHW71O-AHW71Q, adjusting Brake piston and wear indicator, basic setting Brake system, basic check Brake system, bleeding 2 Brake system, bleeding (2) Brake system, bleeding 1 Brake system, bleeding Brake system, checking function, hydraulic (2) Brake system, checking function, hydraulic Brake system, relieve pressure Brake system, specifications Brakes A35D wet brakes and A40D, description Brakes A35D, description Brakes, specification, A40D (AHW71L–AHW71N, AHW71O–AHW71Q) Cab description Cab door, installing door catch Cab door, removing door catch Cab, lifting points (2) Cab, lifting points Cabin, specification Camshaft sensor, changing (2) Camshaft sensor, changing Camshaft setting, checking Camshaft, checking wear Camshaft, description (2) Camshaft, description Camshaft, replacing Capacities, A40D Carbon monoxide in fuel system, check CareTrack Telematics system 1 CareTrack Telematics system Casing, new type for headlamps C-ECU, MID178, changing non-Programd ECU (2) C-ECU, MID178, changing non-Programd ECU C-ECU, MID178, changing pre-Programd ECU (2) C-ECU, MID178, changing pre-Programd ECU CE-marking, EMC-directive Central warning Change of crankshaft seal Change specifications V2002.3.0, change specification V2002.4.0, change specification V2004.4.0, change specification V2004.6.0, change specification V2005.2.0, change specification V2005.3.0, change specification V2005.5.0, change specification V2005.6.0, change specification V2006.1.0, change specification V2006.3.1, change specification V2006.3.2, change specification V2006.3.3, change specification V2006.5.0, change specification V2006.6.0, change specification V2006.6.1, change specification V2007.1.0, change specification Changing or repairing hydraulic pumps Charge air pressure, diesel engines Charge-air cooling Checking for leaks with inspection light (2) Checking for leaks with inspection light Checking main, torque converter and lubrication oil pressure Checking of main, torque converter and lubricating oil pressure Checking stalling speed 1 Checking stalling speed Checklist after a fire or heat exposure Claim routines Cleaning of the machine Cleanliness, brake and hydraulic systems Cold-start device, specifications Collection of basic data Combined control by steering wheel, changing (2) Combined control by steering wheel, changing Communication, vehicle electronics Component and description (2) Component and description Component descriptions (2) Component descriptions Component positions Component position 1, AL3201–HE8501 Component position 2, IA–LA3601 Component position 3, LA3602–LC4202 Component position 4, LC4601–MA4207 Component position 5, MA4302–PWM4204 Component position 6, R3501–SA4201 Component position 7, SE2202–SE5202 Component position 8, SE5203–SO3901 Component position 9, SW2502–SW4215 Component position 10, SW4301–SW9102 Components, list and positions Compressed air diagram (2) Compressed air diagram Compressed air diagram 1 Compressed air diagram 2 Compressed air drier, service solution Compressed air system, pressure build-up (2) Compressed air system, pressure build-up Compressed-air system, specifications Compression test Compressor, replacing Condition test and maintenance program Connecting disconnecting vacuum pump - instructions Connector for cooling fan PWM valves Connectors C01–DY, position Connectors EA–F50, position Connectors HE3601–TAILR, position Connectors, overview Control unit, transmission T–ECU, description of function Control units, hardware Control units, voltage supply (2) Control units, voltage supply Contronic socket, mounting plate Conversion tables Coolant circulation, description (2) Coolant circulation, description Coolant filter, changing (2) Coolant filter, changing Coolant pump removed, reconditioning Coolant pump, description (2) Coolant pump, description Coolant with freezing and corrosion protection Coolant, changing (2) Coolant, changing Cooling fan motor, intercooler, adjusting high speed Cooling fan motor, intercooler, adjusting low speed Cooling fan motor, intercooler, checking adjusting high rpm Cooling fan motor, intercooler, checking adjusting low rpm Cooling fan motor, intercooler, checking high speed Cooling fan motor, intercooler, checking low speed Cooling fan motor, radiator, checking adjusting high rpm Cooling fan motor, radiator, checking adjusting low rpm Cooling system specifications Cooling system, flushing Cooling system, principle illustrations (2) Cooling system, principle illustrations Cooling system, tightening torques Cooling unit, performance test Crank mechanism, description Crankshaft, replacing rear oil seal (2) Crankshaft, replacing rear oil seal Crimping Tool Set, part no. 9993880 Cylinder balancing, PC test Cylinder block, description (2) Cylinder block, description Cylinder compression, PC test (2) Cylinder compression, PC test Cylinder head, description (2) Cylinder liner, description (2) D¿ECU, Functions D9B and D12D Stage 3, valve adjustment, camshaft marking D12C, New connecting rod D12C-D12D, Belt protector, new bracket D12D Stage III, new turbo installation Damping cylinder, changing seal Damping cylinder, changing seals Damping cylinder, checking pre-load (2) Damping cylinder, checking pre-load Damping cylinder, specification Damping cylinder Data bus system Data buses, function (2) Data buses, function Data buses, voltage levels (2) Data buses, voltage levels Dealers retrofitter´s responsibility Decontamination Description clutch Description cooling unit Description retarder Description steerring Description transmission (2) Description transmission 1 Description transmission Description, components Description, retarder (2) Description, retarder Description Diesel fuels - quality and function Differential carrier assembly, replacing (2) Differential carrier assembly, replacing Digital input and output signals (2) Digital input and output signals Dimensional diagram A40D Dimensions for A35D with 26.5 R-25 tyres Dimensions for A40D with 29.5 R-25 tyres Dipstick, transmission Display unit and keyboard (2) Display unit and keyboard Display unit, content Dog-clutch for six-wheel drive (6x6), checking and adjusting (2) Dog-clutch for six-wheel drive (6x6), checking and adjusting Door lock, replacing Door lock Door window, replacing (2) Door window, replacing Door, replacing Double rocker arm, description Draining refrigerant R134a, with scales 9812513 Draining refrigerant R134a Drawings of E-tools Drive axles A40D Drive axles, capacity Drivetrain, description DROPBOX FL852-862 Bearing retainer for reverse gear output shaft, reconditioning Brackets, fitting Casing, fitting Casing, reconditioning Differential bearing clearance, adjusting Differential bearing retainer, reconditioning Differential coupling sleeve, changing ball bearing Differential lock and sensor, adjusting Differential, reconditioning Dropbox, reconditioning Forward speed output shaft bearing retainer, reconditioning Forward speed output shaft, adjusting bearing clearance Forward speed output shaft, fitting Forward speed output shaft, reconditioning High low control (FL862), fitting High low shifting sensor, adjusting (FL852) High low shifting sensor, fitting High-low control, fitting (FL852) High-low shifting sensor (FL862), adjusting High-low transmission cover (FL862 only), reconditioning Input shaft and layshaft, fitting bearing races Input shaft follower (FL862), fitting Input shaft, adjusting bearing clearance Input shaft, reconditioning Layshaft, adjusting bearing clearance Layshaft, fitting Layshaft, reconditioning Longitudinal differential lock coupling sleeve, reconditioning Longitudinal differential locks, fitting Lubricating oil pipe, fitting Lubricating oil pump cover, checking Lubricating oil pump cover, fitting Output shaft, reverse gear, reconditioning Reverse gear output shaft with tubular shaft, assembling Reverse gear output shaft, bearing adjustment Sensor, fitting Shift fork (high-low), reconditioning Shift fork for differential lock, reconditioning Shift fork for high-low gear, fitting Suction pipe, fitting Suction strainer, reconditioning Tubular shaft, adjusting Tubular shaft, reconditioning Dropbox FL1002 FL992, new differential casing Dropbox, capacities Dropbox, general (2) Dropbox, general Dropbox, mounting Dropbox, new differential Dropbox, new housing for longitudinal differential lock Dropbox, position sensor high low Dropbox, removing (2) Dropbox, service solution, reinforcement of bracket Dropbox, specifications Dropbox, weights FL 852 FL 862 Dropbox, weights FL 992 FL 1002 Dump body alternative, lowering Dump body joint, changing tipping bearing Dump body position indicator, adjusting Dump body, adjusting against frame (2) Dump body, adjusting against frame Dump lever, changing (2) Dump lever, changing 1 Dump lever, changing Dump lever, description (2) Dump lever, description Dump lever, specifications E1763, Drain hose E2502, Installation tool for turbine speed sensor E-2516 Measuring nipple E-2519 Measuring nipple E–ECU D12, Functions E–ECU D12C, Input and Output terminals E–ECU D12D, Input and Output terminals (2) E–ECU D12D, Input and Output terminals E-ECU, changing (2) E-ECU, changing E–ECU, Control unit engine E-ECU, MID 128, changing non-Programd ECU E-ECU, MID 128, changing non-Programd ECU E-ECU, MID 128, changing pre-Programd ECU 1 E-ECU, MID 128, changing pre-Programd ECU 2 Electric engine hood pump, changing 1 Electric engine hood pump, changing Electric hood pump, changing Electrical distribution box, description (2) Electrical distribution box, description 1 Electrical distribution box, description Electrical symbols and designations (2) Electrical symbols and designations Electrical system 1 Electrical system and electronic system, introduction Electrical system, basic check (2) Electrical system, basic check Electrical system, description, general Electrical system, special instructions for servicing, actions when working on machine (2) Electrical system, special instructions for servicing, actions when working on machine Electrical system, special instructions for servicing, electrical components, alternator and charging regulator (2) Electrical system, special instructions for servicing, electrical components, alternator and charging regulator Electrical system, special instructions for servicing, electrical components, batteries Electrical system, special instructions for servicing, electronic components Electrical system, special instructions for servicing, general (2) Electrical system, special instructions for servicing, general Electrical system, specifications Electrical system Engine and transmission, installing Engine and transmission, mounting Engine and transmission, removing (2) Engine and transmission, removing Engine cable harness D12C Engine control unit D12, E–ECU, description of function (2) Engine control unit D12, E–ECU, description of function Engine D12, description (2) Engine D12, description Engine D12C Adjusting, general 1 Bushing rocker arm shaft, checking Camshaft, checking wear Connecting rods, checking Crankshaft, checking Cylinder head, reconditioning Cylinder heads all, fitting Cylinder heads all, removing Cylinder liner, checking and measuring wear Engine, assembling Engine, dismantling Flywheel housing with power take-off, installing Flywheel housing with power take-off, removing Flywheel housing, installing Flywheel housing, removing Oil cooler core, leakage check Pistons and crankshaft, removing Pistons, checking Timing gear, installing Timing gear, removing Unit injectors, checking Valves, adjusting 3 Engine D12D Adjustment d12d Camshaft, checking wear d12d Connecting rods, checking d12d Crankshaft, checking d12d Cylinder head, reconditioning d12d Cylinder heads all, fitting d12d Cylinder heads all, removing d12d Cylinder liner, checking and measuring wear d12d Engine, assembling d12d Engine, dismantling d12d Engine, mounting resp Flywheel housing with power take-off, installing d12d Flywheel housing with power take-off, removing d12d Flywheel housing, installing d12d Flywheel housing, removing d12d Oil cooler core, leakage check d12d Pistons and crankshaft, removing d12d Pistons, checking d12d Rocker arm mechanism removed, reconditioning d12d Timing gear, installing d12d Timing gear, removing d12d Unit injectors, checking d12d Valves, adjusting d12d Engine hood, installing Engine hood, removing Engine identification Engine mounting rear, changing Engine oil requirements Engine oil, altered time for the first oil change Engine oil, interval between changes Engine reconditioning Engine screens Engine speed sensor, changing (2) Engine speed sensor, changing Engine timing gear, description (2) Engine timing gear, description Engine transmission, specification Engine, basic check (2) Engine, basic check Engine, fill quantities Engine, general specifications Engine, identification Engine, installing (2) Engine, installing Engine, removing Engine Environment Environmental handling for the future Environmentally hazardous fluids Environmentally safe handling Evaporator, replacing incl draining and filling Exhaust pressure governor (2) Exhaust pressure governor Exhaust system suspension, rubber cushion Explanation of wiring diagrams (2) Explanation of wiring diagrams Explanations to hydraulic diagram (2) Explanations to hydraulic diagram Fan belt and or alternator belt, checking and adjusting tension Fan motor, changing Fan motor, replacing Fan regulator, PWM2601 and PWM2602 Fan system, description Fan, new type Fault diagnosis, air conditioning system (AC) Feed pressure, PC test Feed pump, checking feed pressure Filter head D12D, description (2) Filter head D12D, description Fire prevention measures FL1002 and FL992, new seals Flywheel, tightening torques Foot brake valve, description Foot brake valve, replacing Frame joint, separating the machine Front axle (2) Front axle rear axle, weights Front axle Front output shaft on dropbox, changing seal (2) Front output shaft on dropbox, changing seal Front underbody skid plate, mounting (2) Front underbody skid plate, mounting Front underbody skid plate, removing (2) Front underbody skid plate, removing Fuel feed pump, description Fuel feed pump, specifications Fuel filter and water separator replacement interval change Fuel filter housing, description Fuel filter, description Fuel flow D12C (2) Fuel flow D12C Fuel flow D12D Fuel flow, description Fuel pump (valves), inspection Fuel pump, inspection Fuel system components Fuel system, bleeding Fuel system, bleeding 1 Fuel system, bleeding 2 Fuel system, description (2) Fuel system, description Fuel system, specifications Fuel system's components Function of the valves (2) Function of the valves Function of unit injectors (2) Function of unit injectors Gear Fs Gear F1 Gear F2 Gear F3 Gear F4 Gear F5 Gear F6 Gearshift selector, changing (2) Gearshift selector, changing General instructions for controls, replacing. (2) General instructions for controls, replacing. General maintenance instructions General vehicle electronics (2) General vehicle electronics Grease with molybdenum disulphide additive (MoS2) Grease-lubricated hitch Grounding points (frame connections) Group 0, setup screens Group 1, service screens Group 2, screens, engine Group 3, screens, electrical system Group 4, screens, transmission Group 5, screens axles brakes Group 8, screens Operating Information Group 9, hydraulic screens Guide pins D12D Headlamp, high and low beams, adjusting Headlamp, high beam, replacing (2) Headlamp, high beam, replacing Headlamp, low beam, replacing (2) Headlamp, low beam, replacing Headlamp, new light bulb Health hazards with paint, plastics and rubber Heat control valve, fitting Heat control valve, removing Heat control valve, replacing Heat control, replacing Heater control, mounting Heater control, removing Heater core, replacing Heater, changin Hitch, specifications (2) Hitch, specifications 1 Hitch, specifications Hitch, tightening torque Hitch, tightening torques 1 Hitch, tightening torques Hoist cylinder bearing, changing Hoist cylinder bearing, changing 1 Hoist cylinder bearing, changing 2 Hoist cylinder removed, reconditioning (2) Hoist cylinder removed, reconditioning Hoist cylinder, description Hoist cylinder, installation Hoist cylinder, removal Hoist cylinder, replacement Hoist cylinder, specification Hoist cylinder Hub end, cross-section AH64J – AH64L Hub end, cross-section AHW64M – AHW64O Hub end, cross-section AHW71L – AHW71N (2) Hub end, cross-section AHW71L – AHW71N Hub end, cross-section AHW71O – AHW71Q (2) Hub end, cross-section AHW71O – AHW71Q Hub reduction gear, new seal and spacer ring Hub reduction gear, planet carrier, new design Hydraulic and servo systems, description (2) Hydraulic and servo systems, description Hydraulic brake system, pressure build-up (2) Hydraulic brake system, pressure build-up Hydraulic components, cleanliness when handling Hydraulic components, storage and transport Hydraulic cooling fan control, PC test Hydraulic diagram PT (2) Hydraulic diagram PT Hydraulic diagram, brake system, dry brakes Hydraulic diagram, brake system, wet brakes (2) Hydraulic diagram, brake system, wet brakes Hydraulic diagram, brake system, wet brakes 1 Hydraulic diagram, brake system, wet brakes 2 Hydraulic diagram, complete (2) Hydraulic diagram, complete 1 Hydraulic diagram, complete 3 Hydraulic diagram, complete Hydraulic diagram, complete 1 Hydraulic diagram, complete 2 Hydraulic diagram, hood opening Hydraulic oil filter, changing Hydraulic oil, description Hydraulic oil, storing and handling Hydraulic pressure, specifications Hydraulic pump (removed), changing shaft seal Hydraulic pump, changing Hydraulic pump, checking and adjusting max working pressure (2) Hydraulic pump, checking and adjusting max working pressure 1 (2) Hydraulic pump, checking and adjusting max working pressure 1 Hydraulic pump, checking and adjusting max working pressure Hydraulic pump, checking and adjusting standby pressure (2) Hydraulic pump, checking and adjusting standby pressure Hydraulic pump, description (2) Hydraulic pump, description 1 Hydraulic pump, description Hydraulic pump, removed, changing shaft seal Hydraulic pump, replacing Hydraulic pump, replacing 1 Hydraulic pump, replacing 2 Hydraulic pump, replacing Hydraulic pumps, specifications Hydraulic pumps, specifications 1 Hydraulic pumps, specifications 2 Hydraulic system, bleeding air, version Hydraulic system, bleeding air, version 1 Hydraulic system, bleeding air, version 2 Hydraulic system, capacities Hydraulic system, description (2) Hydraulic system, description Hydraulic system, relieve pressure Hydraulic system, repair of hydraulic components in workshop Hydraulic system, service update Hydraulic system, updating Hydraulic system, work instructions Hydraulic tank, description Hydraulics screen Hydraulics Identification number I-ECU, MID 140, changing non-Programd ECU I-ECU, MID 140, changing pre-Programd ECU I-ECU, MID140, changing non-Programd ECU I-ECU, MID140, changing pre-Programd ECU Improvements, frame joint Induction sensor for turbine speed, changing Information display unit, general (2) Information display unit, general Information on Bio-diesel fuel (RME-fuel) Information on classification of oils Information, build-up (2) Information, build-up Initial display and settings Injector shut off, manual Injectors, replacing copper sleeve in machine Input shaft on dropbox, changing seal (2) Input shaft on dropbox, changing seal Instructions for repairing Instructions for working with electronic fuel injection (2) Instructions for working with electronic fuel injection Instrument control unit ECU, functional description Instruments and controls, climate control panel Instruments and controls, left instrument panel Instruments and controls, main instrument (2) Instruments and controls, main instrument Instruments and controls, overview (2) Instruments and controls, overview Instruments and controls, right instrument panel (2) Instruments and controls, right instrument panel Instruments and operating controls, left instrument panel and steering wheel column Intercooler, description Intercooler, replacing Intercooler, specifications Intermediate shaft A35D-A40D, new bearing and grease Intermediate shaft and or bearing, changing Intermediate shaft andor bearing, replacing Intermediate shaft, cut-away view (2) Intermediate shaft, cut-away view Intermittent retarder function, PT1563, 1863 Internal Exhaust Gas Recirculation (IEGR), description KAB Seat, heater range Key functions (2) Key functions Lap belts Lifting machine, A35D (2) Lifting machine, A40D (2) Lifting tool, new marking Lifting tool, new type Lifting tool, transmission Lighting, specifications Load and dump brake, checking and adjusting working pressure (2) Load and dump brake, checking and adjusting working pressure Load body position indicator, adjusting Load body, changing dump bearing Load body, emergency lowering 1 Load body, emergency lowering Load unit frame (2) Load unit frame Lock-up clutch (2) Lock-up clutch Longitudinal differential lock, checking and adjusting - from underneath (2) Longitudinal differential lock, checking and adjusting - from underneath Lubricant, Biodegradable Hydraulic Fluid Lubrication and service schedules Lubrication system, description Lubrication system, principle (2) Lubrication system, principle Lubrication system, specifications Lubrication, see lubrication chart Maintenance service Maintenance service, daily Maintenance service, every 50 hours Maintenance service, every 250 hours Maintenance service, every 500 hours Maintenance service, every 1000 hours Maintenance service, every 2000 hours Manual release of parking brake Measuring nipples, new type Mechanical operator's seat, adjusting Mechanical release of parking brake Menu tree (2) Menu tree Messages and information content (2) Messages and information content New AC hoses and new attaching rail New clamping on coolant pipe New coolant New coolant 1 New coolant 2 New cross stay, trailer unit New display screen for transmission oil level New dropbox New engine hood New fan installation New floor panel and floor mat New hauler, A40D New hoist cylinder New hub nut locking New Intercooler Hoses New keypad New main fuel filter, D9, D12 and D16 New non-return valve with back-pressure function, MTRV1 New oil dipstick New pressure sensors New resistor for the alternator's charging circuit New seals for steering joint bearings New sensor for accelerator and retarder pedal New starter switch New tipping spool, valve block New tool Electrical repair kit, part No. 11666200 New transmission New transmission 1 New transmission 2 New transmission 3 New transmission 4 New turbocharger for the D12 engine New unit injectors New VCB valve, MA2503 New Volvo standard for transmission oil New warranty routines for Bosch diesel equipment New water trap New wiper motor Noise reduction kit Non-return valve function in steering and dumping valve Oil analyses Oil and seals AH64J-AH64L Oil cooler, replacing Oil cooler, replacing 1 Oil cooler, replacing Oil cooler, specifications Oil cooler, tightening torques Oil jet nozzle eliminated from the D12D and D9B exhaust double rocker arm Oil leakage from the engine cable harness grommet Oil level sensor, changing (2) Oil level sensor, changing Oil pump and oil cooler (2) Oil pump and oil cooler Oil sampling, method Oil sampling, sampling points Oil sump gasket, changing (2) Oil sump gasket, changing Oil sump, tightening torque Oils and seals AHW64M – AHW64O Oils and seals AHW71L – AHW71N (2) Oils and seals AHW71O – AHW71Q Operating information and service Operator's seat, changing air spring Operator's seat, changing the air spring Operator's seat, installing Operator's seat, removing Operator's seat, removing 1 Operator's seat, removing 2 Other fuses and relays, description (2) Other fuses and relays, description 1 Other fuses and relays, description Output shaft 6-wheel drive, changing bearing (2) Output shaft 6-wheel drive, changing bearing Overflow valve, checking Parking brake lever, changing (2) Parking brake lever, changing Parking brake, basic check (2) Parking brake, basic check Parking brake, description Parking brake, new brake pads Parking brake, replacing brake disc Parking brake, replacing brake pads (2) Parking brake, replacing brake pads Parking brake, specifications Personal competence and accreditation (2) Personal competence and accreditation Pipe for dipstick for transmission Pipe, secondary water pump Pistons, description (2) Pistons, description Planetary gear Planetary gears Portable refillable O-ring kits Position monitor high low range, adjusting (2) Position monitor high low range, adjusting Power take-off, between engine and gearbox, reconditioning Power take-off, tightening torque Power transmission, basic check Power transmission, specifications Preheating coil, replacing Preheating coil Preheating Pressure accumulation (2) Pressure accumulation Pressure build-up, engine-dependent pumps, description (2) Pressure build-up, engine-dependent pumps, description 1 Pressure build-up, engine-dependent pumps, description Pressure check connections, description (2) Pressure check connections, description Pressure check connections, description 1 Pressure check connections, description Pressure tables, transmissions Pressurizing with nitrogen gas Product development Product development 1 Product development Product identification plates Product update Dropbox FL1002 992, Longitudinal differential lock Propeller shaft, tightening torque Propeller shaft Proportional valve, description Protection against electromagnetic interference PT2509, 1563, 1863, reinforced planet kit, stage 1 PT2509, PT1563 and PT1863 new design of spring pins in planet kit stage 2 and 3 PTO, gear shaft assembly update PTO, o-rings update Pump regulator, checking Quality of illustrations in technical reports Radiator, adjusting Radiator, description (2) Radiator, description Radiator, installation Radiator, mounting (2) Radiator, mounting Radiator, removal Radiator, removal Radiator, removing 1 Radiator, removing Rear output shaft on dropbox, changing seal (2) Rear output shaft on dropbox, changing seal Rear window pane, replacing Receiver, replacing incl draining and filling Recommended lubricants Recovering and towing (2) Recovering and towing Recycling station FRS-10GS Refilling refrigerant in the AC system, with scales 981 2513 Refrigerant for air conditioning (2) Refrigerant for air conditioning Refrigerant R134a, vacuum pumping including filling (charging) Refrigerant, filling incl vacuum pumping Repair instructions Repair kit, part no. 11666145, for service display Replacement of pivot pin for accelerator pedal and retarder pedal Replacement of solenoid valve MA9102 Replacing damping cylinder Reporting of accidents and incidents Reporting of product misuse & near-miss report Reverse gear R1 (2) Reverse gear R2 (2) Rocker arm piston, D12C (2) Rocker arm piston, D12C Rocker arm shaft, tightening torques Routine for return of technical goods Rubber bearings, cross stay Rubber cushion, replacing Rules when handling tyres SAE J1708 (Information bus) SAE J1939 CAN-bus (control bus) Safety concerns Safety concerns everybody! Safety during electric welding Safety when handling accumulators Safety when handling oils and fuel Safety when handling the machine Safety when lifting and supporting the machine Safety when servicing Safety when using lifting equipment Safety when working on hydraulic systems Safety when working on pressurized systems Safety when working on the machine's electrical system Safety when working with air conditioning refrigerant Safety when working with air-conditioning refrigerant Safety when working with batteries Scales 9812444 Seal for rear output shaft, replacing Secondary steering, checking and adjusting max. pressure and stand-by pressure Secondary steering, checking and adjusting max Section 4, content, structure Service and maintenance of batteries Service connection and programming connection (2) Service connection and programming connection Service display unit Contronic, navigator Service display unit, general (2) Service display unit, general Service display unit, summary Service journal (included in Operator's manual), fill in Service Manual, supplement Service position Service solution for high altitude Service tools Service Shut-off P1 at low engine rpm (MA9102), checking function Side window, replacing Software versions and ECUs part number, checking Software versions and ECUs part number, general Software versions and ECUs part number, list Software, introduction Special tools Spring for longitudinal differential lock in dropbox Stall speed, checking Standard tightening torques Start electronics (2) Start electronics Starter motor, replacing (2) Starter motor, replacing Starter motor, specification Starter motor, tightening torques Starting with booster batteries Steering and dumping valve, changing 1 Steering and dumping valve, changing Steering and dumping valve, description Steering and dumping valve, overview illustration Steering and dumping valve, removed, reconditioning Steering and dumping valve Steering and dumping valve, changing Steering and dumping valve, description 1 Steering and dumping valve, description 2 Steering and dumping valve, overview illustration 1 Steering and dumping valve, overview illustration 2 Steering and dumping valve, removed, reconditioning 1 Steering and dumping valve, removed, reconditioning 2 Steering and dumping valve, specifications Steering and dumping valve, tightening torques Steering and hydraulics, basic check Steering and tipping valve, installation Steering and tipping valve, removal Steering angle, checking and adjusting Steering cylinder bearing, introduction of grease nipples Steering cylinder, description Steering cylinder, reconditioning on machine (2) Steering cylinder, reconditioning on machine Steering cylinder, removed, reconditioning (2) Steering cylinder, removed, reconditioning Steering cylinder, replacing bearing, left-hand side (2) Steering cylinder, replacing bearing, left-hand side Steering cylinder, replacing Steering cylinder, specifications Steering gear, check.and adj. Steering gear, replacing Steering gear, specifications Steering joint bearing, replacing (2) Steering joint bearing, replacing Steering joint bearing Steering joint spherical bearings, checking clearance (2) Steering joint spherical bearings, checking clearance Steering joint, vertical joint, introduction of grease nipples Steering linkage, checking and adjusting (2) Steering linkage, checking and adjusting Steering linkage, checking and adjusting 1 Steering linkage, checking and adjusting Steering system, description Steering system, specifications Steering times, checking and adjusting Steering valve, neutral position, checking and adjusting Steering, rack and pinion gear, changing Stop electronics (2) Stop electronics Suspension, description Suspension Tank T-ECU, MID 130, changing non-Programd ECU T-ECU, MID 130, changing pre-Programd ECU T-ECU, MID130, changing non-Programd ECU T-ECU, MID130, changing pre-Programd ECU The torque converter Theft protection (2) Theft protection Thermostat, description Thermostat, primary system, description (2) Thermostat, primary system, description Thermostat, primary system Thermostat, replacing Thermostat, secondary system, description (2) Thermostat, secondary system, description Thermostat, secondary system Thrust washer and wear ring, axles Tightening torque, cylinder head Tightening torque, fuel system Tightening torques, engine mounts Tightening torques, engine mounts 1 Tightening torques, engine mounts 2 Tightening torques, valve cover Timing gear case, fitting new gasket in machine Tractor unit frame (2) Tractor unit frame Transmission and dropbox Transmission of power (2) Transmission of power Transmission PowerTronic, new B2 drum Transmission PowerTronic, new gasket Transmission PT Brake B1 and clutch K2, installing Brake B2 and B3 as well as planet stage 1 and 2, installing Brake B4 and planet stage 4 and 5 as well as output shaft, installing PT1560 PT1860 Brake drum B2, reconditioning Brake piston B1, reconditioning Brake piston B2–B3, reconditioning Brake piston B4, reconditioning Clutch K1, installing Clutch K1, reconditioning Clutch K2, reconditioning Connector EH and cabling, installing Control system, installing Control system, reconditioning PT1560 PT1860 Control system, reconditioning PT1862 Difference description of PT transmission General repair instructions transmission Hydraulic diagram PT1560, PT1860 and PT1862 Middle support, installing Oil pump, reconditioning Output shaft and rear cover, installing PT1862 Output shaft, reconditioning PT1862 Planet kit, stage 1, 2, 3 and 5, reconditioning Planet stage 1, reconditioning Planet stage 2, reconditioning Planet stage 3 and main shaft, installing Planet stage 3, reconditioning Planet stage 4, 5 and brake B4, installing PT1862 Planet stage 4, reconditioning PT1862 Planet stage 5, reconditioning PT1862 Planet stage, stage 1–5, checking Planet stages 4, 5 and output shaft, reconditioning PT1560 PT1860 Rear cover, installing PT1560-PT1860 Rear cover, reconditioning PT1560 PT1860 Rear cover, reconditioning PT1862 Reshimming PT1560 PT1860 with E–tool Reshimming PT1560 PT1860 without E–tool Reshimming PT1862 Retarder counterhold, reconditioning Retarder valve, installing Retarder valve, reconditioning Retarder, checking Retarder, installing Stator shaft, oil pump and seal shield, installing Stator shaft, reconditioning Torque converter, installing Transmission dismantling Transmission PT1663, reinforced bolted joint, converter housing – transmission housing Transmission PT1860, cut-away Transmission PT1862, cut-away view Transmission PT1862, cut-away Transmission, adaptive gear shifting Transmission, capacities Transmission, clutches and brakes (2) Transmission, clutches and brakes 1 Transmission, clutches and brakes Transmission, functional check Transmission, improved retarder Transmission, inspection form Transmission, installing from above (2) Transmission, installing from above Transmission, installing from underneath (2) Transmission, installing from underneath Transmission, oil pressure Transmission, removing downward (2) Transmission, removing downward Transmission, removing upward (2) Transmission, removing upward Transmission, specifications Transmission, weights Transmission Transporting the machine Transverse differential lock axle, checking and adjusting Transverse differential lock-axle, checking and adjusting Troubleshooting strategy Troubleshooting tips 1 Troubleshooting tips Troubleshooting, air conditioning unit (AC) Troubleshooting, assistant devices Troubleshooting, general Turbocharger (2) Turbocharger, inspection Turbocharger, overview illustration Turbocharger, replacing Turbocharger, specifications Turbocharger Tyre equipment and recommended tyre pressures Tyres, various types Unit injector, adjusting pretension Unit injector, Bosch, description (2) Unit injector, Bosch, description Unit injector, Delphi, description Unit injector, replacing Unit injectors, specifications Vacuum pump, connection Vacuum pump, disconnection Vacuum-pumping as well as refilling AC oil, with scales 9812513 Valve mechanism, description Valve mechanism, double rocker arm Valve mechanism, specifications Valve spring update, D9, D12 and D16 Valves, adjusting (2) Valves, adjusting 1 Valves, adjusting Valves, adjusting 1 Valves, adjusting 2 VCADS Pro service tool, general VCADS Pro tests VCADS Pro, Calibrating VCADS Pro, Error codes VCADS Pro, Programming VCADS Pro, Test VEB, activation (2) VEB, activation VEB, description V-ECU, MID 187, changing non-Programd ECU 1 V-ECU, MID 187, changing non-Programd ECU 2 V-ECU, MID 187, changing pre-Programd ECU 1 V-ECU, MID 187, changing pre-Programd ECU V-ECU, MID187, changing non-Programd ECU Vehicle control unit V¿ECU, functional description Warning screens, axles brakes Warning screens, cab Warning screens, electrical system Warning screens, engine Warning screens, general Warning screens, hydraulic system Warning screens, power transmission Warranty inspection 100 hours Warranty inspection 1000 hours Waste handling Water trap, description (2) Water trap, description Weights, A40D Wheel alignment Wheel, removing and fitting one Wheel, tightening torque Windows, general Windscreen wiper front, replacing motor Windscreen wiper motor, replacing Windscreen wiper motor, tightening torques Wiring diagram Wiring diagram A01 Wiring diagram A02 Wiring diagram A03 Wiring diagram A04 Wiring diagram A05 Wiring diagram A06 Wiring diagram A07 Wiring diagram A08 Wiring diagram A09 Wiring diagram A10 Wiring diagram A11 Wiring diagram A12 Wiring diagram A13 Wiring diagram A14 Wiring diagram A15 Wiring diagram A16 Wiring diagram A17 Wiring diagram A18 Wiring diagram A19 Wiring diagram A20 Wiring diagram A21 Wiring diagram A22 Wiring diagram A23 Wiring diagram A24 Wiring diagram A25 Wiring diagram A26 Wiring diagram A27 Wiring diagram A28 Wiring diagrams description Working in environmentally contaminated areas Working pumps, checking function