Volvo A40E FS Service Repair Manual

Data Size: 151.38 MB
File Type: PDF
Language: English
Manufacturer: Volvo
Applicable Machine: Dump Truck
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Machine Model: Volvo A40E FS Dump Truck
Page: 3994 Pages

1 Descriptions 1.3 1.4 Setting to zero, saved error codes warnings 1.3-1.4 Saved error codes warnings Air cleaner, description Air conditioning AC, basic principles Air conditioning unit, operation FIG 1 Air conditioning unit, operation Air intake and filter Air suspension for operator´s seat, changing Air suspension operator's seat, adjusting Air-conditioning, component location Alternator, description ATC, description Axles and brakes Basic checks Battery, charging Battery, description Brake cooling oil system, description Braking system, description Cab description Cab, lifting points Camshaft, description CareTrack Telematics system Charge-air cooling Cleanliness, brake and hydraulic systems Collection of basic data Component description BRAKES Component descriptions Component position Compressed air system, pressure build-up Connectors, overview Connectors, position Control unit, description Control units, voltage supply Coolant pump, description Cooling fan speed control, description Cooling unit, description 1 Cooling unit, description Crank mechanism, description Cylinder block, description Cylinder head, description Cylinder liner, description Damping cylinder Data bus system Description Digital input and output signals Drawings of E-tools Drive axles, description Drivetrain, description Dump lever, description Electrical cabling and connectors, checking Electrical distribution box, description Electrical system, basic check Electrical system, special instructions for servicing, actions when working on machine 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 Electrical system Electronic control system, special tool measuring, component Electronic control system, special tool measuring, E–ECU Electronic control system, special tool measuring, general Electronic control system, special tool measuring, I-ECU Electronic control system, special tool measuring, T-, V- and V2-ECU Electronic control system, special tool measuring, transmission PT Engine Protection Engine timing gear, description Engine, description Engine, identification Error causes Error code and warning levels Error codes, build-up Error codes, showing Error detection Exhaust pressure governor Foot brake valve, description Frame joint, description Frame, description Fuel feed pump, description Fuel filter housing, description Fuel flow, description Fuel system, description Full Suspension, description General vehicle electronics Hoist cylinder, description Hydraulic and servo systems, description Hydraulic brake system, pressure build-up Hydraulic components, cleanliness when handling Hydraulic components, storage and transport Hydraulic oil, description Hydraulic oil, storing and handling Hydraulic pump flow regulation, description Hydraulic pump, description Hydraulic system, description Hydraulic system, repair of hydraulic components in workshop Hydraulic system, work instructions Hydraulic tank, description Hydraulics Infrared Thermometer Initial display and settings Instruments and controls, climate control panel Instruments and controls, control panel Instruments and controls, left instrument panel Instruments and controls, main instrument Instruments and controls, overview Instruments and controls, right instrument panel Intercooler, description Internal Exhaust Gas Recirculation (IEGR), description Lifting machine Load and dump brake, description 1 Load and dump brake, description Load and Dump brake, function check Lubrication system, description Machine status hardware software Maintenance Measuring symbols, description Measuring, general Non-return valve function in steering and dumping valve Oil trap, description Operating information and service Parking brake, description Parking brake, function description Parking brake, manually releasing Personal competence and accreditation Pistons, description Pressure build-up, engine-dependent pumps, description 1 Pressure build-up, engine-dependent pumps, description Pressure check connections, description 1 Pressure check connections, description Propeller shaft, description Proportional valve, description Protecting plate, description PWM5901, description Radiator, description Rear view monitor, service menu Recovering and towing Refrigerant for air conditioning Refrigerant, draining Relieve pressure Repair instructions AC Retarder pedal, description Retarder, description SAE J1708 (Information bus) SAE J1939 CAN-bus (control bus) Safety when working with air-conditioning refrigerant Service connection and programming connection Service display unit, general Service display unit, summary Service position 2 Service Software versions and ECUs part number, checking Software versions and ECUs part number, general Software versions and ECUs part number, list Starting with booster batteries Steering and dumping valve, description Steering cylinder, description Steering system, description Suspension cylinder, description 1 Suspension cylinder, description Thermostat, description Transfer gearbox, description Transmission, cut-away drawing Transmission Troubleshooting strategy Troubleshooting, assistant devices Troubleshooting, general Turbocharger, description Unit injectors, description V2007.3.0, change specification V2007.4.0, change specification V2007.5.0, change specification V2007.6.0, change specification V2008.1.0, change specification V2008.3.0 V2008.3.1, change specification V2008.4.0, change specification V2009.4.0, change specification Valve mechanism, description VCADS Pro service tool, general VCADS Pro tests VCADS Pro, Calibrating VCADS Pro, Error codes VCADS Pro, Programming VCADS Pro, Test Warranty inspection Wheel brake, function description Windows, general Working lights, description Diagrams Brake cooling oil system, diagram - 1 Brake cooling oil system, diagram Components, list and positions Compressed air diagram Compressed air diagram-1 Compressed air diagram-2 Compressed air diagram-2-2 Electrical symbols and designations Explanation of wiring diagrams Grounding points (frame connections) Hydraulic diagram PT Hydraulic diagram PT-1 Hydraulic diagram PT-1-1 Hydraulic diagram, brake system 2 Hydraulic diagram, brake system 2-2 Hydraulic diagram, brake system 3 Hydraulic diagram, brake system 3-3 Hydraulic diagram, brake system Hydraulic diagram, brake system-1 Hydraulic diagram, complete 2 fig 1 Hydraulic diagram, complete 2 Hydraulic diagram, complete 3 fig 1 Hydraulic diagram, complete fig 1 Hydraulic diagram, complete fig 3 fig 1 Hydraulic diagram, complete Hydraulic diagram, hood opening MS.Internal.Documents Steering and dumping valve, overview illustration Wiring diagram A01 Wiring diagram A02 1 Wiring diagram A02 Wiring diagram A03 1 Wiring diagram A03 Wiring diagram A04 Wiring diagram A04-1 Wiring diagram A05 Wiring diagram A05-1 Wiring diagram A06 Wiring diagram A07 Wiring diagram A07-1 Wiring diagram A08 Wiring diagram A09 Wiring diagram A09-1 Wiring diagram A10 Wiring diagram A11 Wiring diagram A11-1 Wiring diagram A12 Wiring diagram A13 Wiring diagram A14 Wiring diagram A15 Wiring diagram A16 Wiring diagram A17 Wiring diagram A18 Wiring diagram A18-1 Wiring diagram A18-2 Wiring diagram A18-3 Wiring diagram A19 Wiring diagram A20 Wiring diagram A21 Wiring diagram A21-1 Wiring diagram A21-2 Wiring diagram A22 Wiring diagram A23 1 Wiring diagram A23 Wiring diagram A24 Wiring diagram A25 Wiring diagram A27 Wiring diagram A28 Wiring diagram A31 Wiring diagram A32 Wiring diagram A33 Wiring diagram A33-1 Wiring diagram A34 Wiring diagram A34-1 Wiring diagrams Installation Instructions Air cleaner, installing Back up alarm, installing new Cab heater connection 120 V, installing new Cab heater connection 240 V, installing new CareTrack, installing new Engine heater, installing new Extra front spill guard, installing new Fuel filter extra, installing new On board weighing, installing new 1 On board weighing, installing new Radio, installing new Rear view camera, installing new Rear view mirror, installing new Strobe light, installing new Tailgate, overhung, linkage-operated, installing new Tailgate, overhung, wire-operated, installing new Tailgate, underhung, installing new Voltage converter, installing new Repair Accumulator bank, installation Accumulator bank, removal Accumulator removed, checking charging pressure Accumulator, checking Accumulator, discarding Accumulator, installation 1 Accumulator, installation 2 Accumulator, installation Accumulator, precharge pressure, checking and adjusting 1 Accumulator, precharge pressure, checking and adjusting Accumulator, removal 1 Accumulator, removal 2 Accumulator, removal Accumulator, replacing 1 Accumulator, replacing Accumulator, suspension system, discarding Accumulator, suspension system, overhaul Adjusting, general A-frame bushing, front on load unit, changing A-frame bushing, rear on load unit, changing A-frame bushing, tractor unit, replacing Air drier, drier cartridge, replace Air in fuel system, checking Air suspension operator's seat, adjusting Alternator, replacing incl function check Articulated joint, checking clearence Automatic central lubrication, filter, cleaning replacing Auxiliary steering, adjusting working- and stand-by pressure Auxiliary steering, hydraulic pump, installation Auxiliary steering, hydraulic pump, removing Axle mounts, bolted joints, tourque, check Batteries, replacing Battery, charging state, electrolyte level, cables and connections, especially connections at starter motor, check Belts and belt tension, check, replace when needed. Brake cooling circulation, function check Brake cooling oil tank, oil, change 1 Brake cooling oil tank, oil, change Brake cooling oil, level, check Brake disc, replacing Brake pipes and hoses, check Brake system, basic check Brake system, bleeding Brake system, checking function, hydraulic Brake system, pressure oil filter, replace Brake system, relieve pressure Cab door, installing door catch Cab door, removing door catch Cab, air pre-cleaner filter, clean- change Cab, asbestos filter, replacing Cab, installing Cab, main filter, replacing Cab, prefilter, replace Cab, removing Camshaft and flywheel signals, checking with VCADS Pro and oscilloscope Camshaft setting, checking Camshaft, replacing Carbon dioxide in fuel system, check CareTrack antenna, replacing Centre gear , removing and fitting Centre gear, removing and fitting Checking and adjusting the longitudinal differential lock Checking for leaks with inspection light Checking of main, torque converter and lubricating oil pressure Compressor, replacing incl draining and filling Compressor, replacing Condenser, clean (with compressed air) (optional equipment) Condition test and maintenance program Coolant, changing Coolant's freezing point, check Cooling fan motor, intercooler, checking adjusting high rpm Cooling fan motor, intercooler, checking adjusting low rpm Cooling fan motor, radiator, checking adjusting high rpm Cooling fan motor, radiator, checking adjusting low rpm Cooling fan, return oil filter, replacing Cooling system, flushing Cooling unit, performance test Crankshaft, replacing rear oil seal Cross stay, rubber bushing, replacing 1 Cross stay, rubber bushing, replacing Cylinder compression, PC test Cylinder, rear flap, gas pressure, checking and adjusting Damping cylinder, changing seal Damping cylinder, checking spring force Data links, fault tracing with Oscilloscope Differential lock longitudinal, adjustment of sender unit Dog clutch 6x6, checking and adjusting Door lock, replacing Door window, replacing Door, replacing Drive axles, oil, change Drive axles, transmission, dropbox and frame joint, breather filter, replace Dropbox, installing Dropbox, oil, replace Dropbox, removing Dropbox, replacing seal for front otput shaft Dropbox, replacing seal for rear output shaft Dump body alternative, lowering 1 Dump body alternative, lowering Dump body joint, changing tipping bearing Dump body, adjusting against frame Dump lever, changing Dumping lever, checking pressure E-ECU, MID 128, changing non-Programd ECU 1 E-ECU, MID 128, changing non-Programd ECU Electric hood pump, changing Electrical system, basic check Engine and transmission, mounting Engine and transmission, removing Engine hood, installing Engine hood, removing Engine mounting rear, changing Engine mounts dropbox mounts propeller shafts, bolted joints and flange mounts, check torques Engine rotation speed sensor (camshaft), replacing Engine rotation speed sensor, replacing Engine, air cleaner, cover, clean Engine, air cleaner, main filter, replace. EON (option) only replace when indicated. Engine, air cleaner, secondary filter, replace. EON (option) only when indicated Engine, air pre-cleaner, check clean Engine, basic check Engine, oil and filter, change. Evaporator, replacing incl draining and filling Fan belt and or alternator belt, checking and adjusting tension Fan motor, replacing Fan pump, installation Fan pump, removing Feed pressure, PC test Feed pump, checking feed pressure Foot brake valve, replacing Forced Raisin lowering, Full suspension Frame joint bearings, clearance, check Frame joint oil, change Frame joint oil, check Frame joint, changing bearing, machine separated (on load unit frame) Frame joint, measuring and adjusting clearence Frame joint, separating machine Front frame, rear section, cracks, checking FS-cylinder, rubber bearings, check, after first 4000 hours, then after every 1000 hours. Fuel filters, primary and secondary filter, replace Fuel pump (valves), inspection Fuel pump, inspection Fuel system, bleeding Fuel system, extra fuel pre-filter, change Fuel system, extra fuel pre-filter, drainFuel system, extra fuel pre-filter, drain Fuel tank, hydraulic oil tank, brake cooling oil tank, breather filter, replace Fuel tank, sediment, drain. Shorter interval as needed. Fuel, coolant and oil leakage, check Headlights, adjusting Heat control valve, replacing Heat control, replacing Heater core, replacing Hoist cylinder bearing, changing 1 Hoist cylinder bearing, changing Hoist cylinder removed, reconditioning Hoist cylinder, installation Hoist cylinder, removal Hub reduction, installing Hub reduction, removing Hydraulic cooling fan control, PC test Hydraulic cylinder bushing, suspension system, replacing 1 Hydraulic cylinder bushing, suspension system, replacing 2 Hydraulic cylinder bushing, suspension system, replacing Hydraulic cylinder, suspension system, overhaul Hydraulic oil tank, oil, replace if system is filled with mineral oil or Volvo Biodegradable hydraulic oil 46. If system is filled with other biologically degradable hydraulic oil, replace every 2000 hour. Hydraulic oil tank, oil, replace if system is filled with mineral oil or Volvo Hydraulic oil tank, return oil filter, replace, and magnetic rods, clean Hydraulic pump (removed), changing shaft seal Hydraulic pump, checking and adjusting max working pressure 1 Hydraulic pump, checking and adjusting max working pressure Hydraulic pump, checking and adjusting standby pressure Hydraulic pump, replacing Hydraulic system, bleeding Hydraulic system, relieve pressure I-ECU, MID 140, changing non-Programd ECU I-ECU, MID 140, changing pre-Programd ECU Induction sensor for output shaft, changing Induction sensor for turbine speed, changing Injector shut off, manual Injector sleeves, replacing Input shaft seal, replacing Input shaft, seal, replacing Instructions for drilling in ROPS structure Intercooler, replacing Intermediate shaft and or bearing, replacing (in frame joint) Load and Dump brake, servo pressure, checking Load and dump brake, working pressure, checking and adjusting Load body, exhaust heated, check clean grease Load body, rubber cushions, clearance, check Lubrication oil pressure, checking with pressure gauge Lubrication, see lubrication chart 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 Maintenance service, every 4000 hours Maintenance service, every 6000 hours Manual lowering 1 Manual lowering MATRIS, reading, export reading Oil cooler, replacing Oil level sensor, changing Oil sump gasket, changing Oil-bath air cleaner's reservoir (optional equipment), clean, and oil, change Oil-bath air cleaner's reservoir (optional equipment), filter insert, clean Oil-bath air cleaner's reservoir (optional equipment), oil, check Operator's seat, installing Operator's seat, removing Output shaft 6-wheel drive, sealing and bearing, replacing Overflow valve, checking Parking brake , replacing brake caliper Parking brake pads, check Parking brake, basic check Parking brake, function checking Parking brake, replacing brake disc Parking brake, replacing brake pads Position sensor front, replacing Position sensor rear, replacing Position sensor, complete replacement Power take-off suction strainer, cleaning Power take-off, between engine and gearbox, reconditioning Power transmission, basic check Preheating coil, replacing Pressure check connections, description Protecting plate, installation Protecting plate, removal Pump regulator, checking Pump, installation Pump, removal PWM-valve control system, changing Quick coupling compressed air, replacing Radiator, adjusting Radiator, clean (from fan side with compressed air) Radiator, installing Radiator, removing Receiver, replacing incl draining and filling Refrigerant, filling incl vacuum pumping Relief-Cut-in pressure, adjusting Relief-Cut-in pressure, check Rotation speed sensor, adjusting Rotation speed sensor, replacing Rubber cushion, replacing Seal for rear output shaft, replacing Secondary coolant pump, replacing Service brake, brake disc wear, check Service journal (included in Operator's manual), fill in Shift valve, checking Spring brake cylinder, replacing Stall speed, checking Starter motor, replacing Steering and dumping valve, removed, reconditioning 1 Steering and dumping valve, removed, reconditioning Steering and hydraulics, basic check Steering and tipping valve, installation Steering and tipping valve, removal Steering cylinder bearings, clearance, check Steering cylinder removed, reconditioning excl replacing bearings Steering cylinder, installing Steering cylinder, removing Steering cylinder, replacing bearings 1 Steering cylinder, replacing bearings Steering gear, check.and adj. Steering gear, replacing Steering joint bearings, first check of steering joint bearings after 6000 hours. Thereafter every 2000 hours. Steering linkage, checking and adjusting 1 Steering linkage, checking and adjusting Steering times, checking and adjusting Steering valve, neutral position, checking and adjusting Suspension cylinder, installation 1 Suspension cylinder, installation 2 Suspension cylinder, installation Suspension cylinder, removal 1 Suspension cylinder, removal 2 Suspension cylinder, removal Suspension system, bleeding air T-ECU, MID 130, changing non-Programd ECU T-ECU, MID 130, changing pre-Programd ECU Test-run and check Thermostat, replacing 1 Thermostat, replacing Timing gear case, fitting new gasket in machine Transmission, fitting on a non mounted engine Transmission, installing Transmission, oil, main oil filter and lubrication oil filter, replace. Transmission, remove from a non mounted engine Transmission, removing Transverse differential lock axle, checking and adjusting Troubleshooting tips hydraulics Troubleshooting tips Troubleshooting, air conditioning unit (AC) Turbocharger, inspection Turbocharger, replacing Tyres, wear and air pressure, checking Unit injector, replacing Unit injectors, adjusting pretension V2-ECU, MID 249, replacing non-Programd ECU V2-ECU, MID 249, replacing pre-Programd ECU Vacuum pump, connection Vacuum pump, disconnection Valves, adjusting VCADS Pro, logged errors, read off V-ECU, MID 187, changing non-Programd ECU V-ECU, MID 187, changing pre-Programd ECU Warranty inspection 100 hours Warranty inspection 1000 hours Wear indicator, adjusting Wheel brake, replacing Wheel, installing Wheel, removing Windscreen wiper front, replacing motor Working pumps, checking function Service Bulletins Altered wind shield washer tank installation, improved self bleeding Alternative lubricants for axles with wet brakes Automatic transmission lubricants 1 Automatic transmission lubricants Battery and alternator test procedure Check method on engine oil consumption Connection rod self leveling system Diesel fuels - quality and function Face seal leakage, ARB-H35, H40 Final drive, ARB-H axles Frame cracks in steering joint-front frame Fuel sampling, method Ghost codes for E-series Articulated Haulers Grease-lubricated hitch Guide pins D12D Hydraulic connector leakage IL1-IL2 Drop box air leakage on piston, cylinder and sleeve for longitudinal diff Improved Operator's seat Information on Bio-diesel fuel (RME-fuel) KAB Seat, heater range Locking set screw installation on the double rocker arm New accelerator and retarder pedal with gold plated terminals New air horn New camera cable protection New Caretrack WECU2 New clamping on coolant pipe New cross stay, trailer unit New deflector on companion flange New engine software V2010.3.0 New front frame and vertical frame link New fuel filter housing New full suspension sensor New gas spring New haulers, A35E FS and A40E FS New hoist cylinder New Intercooler Hoses New level sensor for full suspension New main fuel filter, D9, D12 and D16 New needle bearings in planet stage 1 New oil sump and level temp sensor for D12D engine New O-ring for ARB-H axles New parking brake valve New pressure sensors New pressure switch for AC system New rear camera system New rear LED flasher New rear view monitor New software update 2011.3.0 for CareTrack New software V2010.2.2 New software version V2008.4.0 New software version V2009.4.0 New starter switch New system design to meet revised ISO 15998 New TechTool VCADS Pro interface New transmission PT2519, Part No. 22418 New wiper motor Oil analyses Oil jet nozzle eliminated from the D12D and D9B exhaust double rocker arm Oil leakage from the engine cable harness grommet Oil sampling, method Premature wear on diff lock control piston seal 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 Quality of illustrations in technical reports Recommendations for Oil Sampling Intervals Repair instruction, rear section front frame Reporting of product misuse & near-miss report Restrictor Washer in FS Distribution block Rubber bearing A-frame Rubber bearings, cross stay Service kit Overhung Tailgate Software and transmission sheets Transmission PN 22401, incorrect machining for output shaft speed sensor SE4307 and H-L-range sensor SE4215 Transmission software update E-series Transmission, functional check Transmission, inspection form Transmission, new main oil pressure sensor SE4219 Tyres, various types Valve spring update, D9, D12 and D16 Volvo Product incidentaccident report & Interview Form Special tool catalog General Index Hooks 1. Enviroment and Safety equipment 2. Measuring equipment 3. Tightening and Loosening tools 4. Lifting equipment 5. Pullers and Pressing equipment 6. Drifts 7. Guide pins and Guide sleeves 8. Pliers 9. Fixtures 10. Tech Tool 11. Spare parts Specifications AC system, specifications Accumulator, specification 1 Accumulator, specification Air cleaner, preheating coil, specifications Alternator, specifications Alternator, tightening torques Axle suspension, tightening torque Axles, specifications Axles, tightening torques Battery, specifications Brake cooling system, specification Brake system, specifications Brakes, specifications Cabin, specification Capacities Cold-start device, specifications Compressed-air system, specifications Cooling system specifications Cooling system, tightening torques Damping cylinder, specification Dropbox, capacities Dropbox, specifications Dump lever, specifications Electrical system, specifications Engine transmission, specification Engine, capacities Engine, general specifications Flywheel, tightening torques Frame joint, tightening torques Front axle rear axle, capacities Fuel feed pump, specifications Fuel tank, volume Hitch, specifications Hoist cylinder, specification Hydraulic pressure, specifications Hydraulic pump brake cooling, specification Hydraulic pumps, specifications Hydraulic system, capacities Hydraulic transmission, capacity Hydraulic transmission, specifications Lighting, specifications Lubricants, specifications Lubrication system, specifications Machine dimensions MS.Internal.Documents Oil cooler, tightening torques Oil sump, tightening torque Parking brake, specifications Power take-off, tightening torque Product identification plates Propeller shaft, tightening torque Protective plate, weight Rocker arm shaft, tightening torques 1 Rocker arm shaft, tightening torques Standard tightening torques Starter motor, specification Starter motor, tightening torques Steering and dumping valve, specifications Steering and dumping valve, tightening torques Steering cylinder, specifications Steering gear, specifications Steering linkage, tightening torque Steering system, specifications Suspension cylinder specifications Thermostat, specifications Tightening torque, cylinder head Tightening torque, fuel system Tightening torque Tightening torques, engine mounts Tightening torques, valve cover Tipping system, specification Transmission oil pressure, specifications Transmission, tightening torques Turbocharger, specifications Tyre equipment and recommended tyre pressures Unit injectors, specifications Valve mechanism, double rocker arm Valve system, specification Weights Wheel, tightening torque Windscreen wiper motor, tightening torques Time Guide Current generation