Volvo A40F and A40F FS Articulated Haulers Workshop Repair Service Manual PDF - MVOLCOA40F.zip

This is a full-service repair manual containing the Electrical Wiring Diagrams for the Volvo A40F and A40F FS Articulated Haulers. Inside, you'll find every technical detail needed to service, troubleshoot, fix, and rebuild these machines just the way professional technicians do.

The workshop service and repair manual for the Volvo A40F / A40F FS Articulated Haulers covers:

* 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.

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MAIN SECTIONS

0 - GENERAL

1 - STANDARD PARTS, SERVICE

2 - ENGINE WITH MOUNTING AND EQUIPMENT

3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS

4 - POWER TRANSMISSION

5 - BRAKE

6 - STEERING

7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT

8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE

9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM

PRODUCT DETAILS:

Total Pages: 3,732 pages

File Format: PDF (Windows & Mac & Linux)

Language: English

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TABLE OF CONTENTS

0 - Foreword......2

0 - GENERAL......3

00 - DESCRIPTION; COMPLETE MACHINE......4

Information and warning decals......5

Product plates......15

Complete machine; descriptions......18

03 - SPECIFICATIONS......21

Tyre equipment and recommended tyre pressures......22

Weights......24

Tightening torques......25

07 - STANDARD TIME......36

Operation numbers for additional work......37

08 - TOOL......39

88830557 User Instruction......40

88830508 User instruction......50

88830507 User instruction......61

88830386 User instruction......69

88830268 User Instruction......74

88830227_88830228 User instruction......80

Leak detector 951 1207; description......90

Infrared Thermometer......94

E-7030......98

E-2546......100

E-2534......102

E-2529......104

E-2526......106

E-2525......108

E-2519......110

E-2518......112

E-2517......114

E-2501......117

E-2014......119

E-2005......121

E-1763......123

1 - STANDARD PARTS; SERVICE......125

16 - LUBRICANT; FUEL; OTHER FLUID......126

Exhaust heated dump body......127

This statement is only valid for Volvo branded engines......128

Recommended lubricants......131

Grease......136

Coolant......137

Automatic lubrication system......139

17 - SERVICE......141

Transporting the machine......145

Propeller shaft between transmission and dropbox; removing......152

Parking brake; manually releasing......158

Dump body alternative; lowering......160

Recovering and towing......163

Automatic central lubrication filter; replacing......166

Fire suppression system; checking......169

Exhaust heated load body; checking; cleaning and greasing......194

Load body rubber cushions clearance; checking......196

Load weighing cable to load cell; checking......198

Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{07-42-07}......199

Hydraulic tank return oil filter and magnetic rod; cleaning and replacing_{07-42-41}......202

Hydraulic tank sediment; draining......208

Hydraulic oil tank breather filter; replacing......210

Hydraulic oil; changing......213

Hydraulic oil level; checking......216

Cab asbestos filter; replacing......217

Cab main filter; replacing......219

Cab prefilter; replacing......221

Alternative exit; checking......223

Tyre wear and air pressure; checking......225

Steering joint bearing; checking......227

Frame joint bearings clearance; checking......231

Frame extension bolted joints torque; checking......234

Secondary steering; checking......236

Steering cylinder bearings clearance; checking......238

Parking brake function; checking......240

Parking brake pads; checking......241

Brake cooling tank return oil filter and magnetic rods; cleaning and replacing_{07-52-35}......243

Brake cooling tank return oil filter and magnetic rods; cleaning and replacing_{07-53-08}......246

Brake cooling oil tank breather filter; replacing......253

Brake cooling oil; changing......255

Brake cooling oil level; checking......259

Brake system pressure oil filter; replacing......260

Service brake disc wear; checking......262

Power take-off suction strainer; cleaning......265

Axle breather filters; replacing......267

Drive axle oil; changing......269

Drive axles leakage; checking......271

Propeller shaft movement; checking......272

Dropbox quick drain valve; replacing......274

Dropbox and front axle; breather filter; replacing......277

Dropbox oil; changing......278

Dropbox leakage; checking......280

Transmission breather filter; replacing......281

Transmission oil filter; replacing......283

Transmission oil; changing......285

Software update; checking......287

MATRIS and Tech Tool; reading......291

Engine and cab heater extra fuel tank breather filter; replacing......293

Engine and cab heater fuel filter; replacing_{08-04-39}......295

Engine and cab heater fuel filter; replacing_{08-05-07}......297

Radiator; cleaning......299

Coolant freezing point; checking......301

Coolant; changing......303

Oil-bath air cleaner reservoir filter insert; cleaning......309

Oil-bath air cleaner reservoir oil; changing......312

Oil-bath air cleaner reservoir oil; checking......315

Engine pre cleaner cyclone type; cleaning......317

Engine air cleaner secondary filter; replacing......320

Engine air cleaner primary filter; replacing......323

Air drier filter; replacing......326

Air drier cartridge; replacing......330

Fuel tank sediment; draining......332

Fuel tank breather filter; replacing_{08-13-17}......334

Fuel tank breather filter; replacing_{08-13-47}......336

Fuel system extra fuel pre- filter; draining......338

Extra fuel prefilter; replacing......340

Fuel filters; replacing......342

Engine oil and filter; changing_{08-16-26}......346

Engine oil and filter; changing_{08-17-00}......349

Engine and dropbox mounts; checking......353

Valves; adjusting_{08-18-50}......356

Drive belts; checking......366

Basic service......368

Lubrication; every 2000 hours......370

Lubrication; every 1000 hours......372

Lubrication; every 500 hours......374

Lubrication; every 250 hours......376

Restoring of the machine......379

Restoring from service position......381

Service position 1 ......383

Maintenance service; every 12000 hours......386

Maintenance service; every 6000 hours......387

Maintenance service; every 4000 hours_{08-25-56}......388

Maintenance service; every 4000 hours_{08-26-25}......391

Maintenance service; every 2000 hours_{08-27-12}......394

Maintenance service; every 2000 hours_{08-27-40}......397

Maintenance service; every 1000 hours......400

Maintenance service; every 500 hours......402

Maintenance service; every 250 hours......404

Maintenance service; every 50 hours......405

Maintenance service; every 10 hours......406

Maintenance service; first 1000 hours......407

Maintenance service; first 100 hours......408

Condition test and maintenance program......409

Tech Tool; operations ......411

Service points......413

Safety when servicing......416

Service_{08-36-31}......418

Service_{08-37-00}......421

19 - GENERAL......423

Decontamination......424

Working in environmentally contaminated areas......428

Safety when working with air conditioning refrigerant......431

Environmentally hazardous fluids......434

Environmentally safe handling......435

Waste handling......437

Environmental handling for the future......441

Environment......443

Health hazards with paint; plastics and rubber......445

Checklist after a fire or heat exposure......448

Fire prevention measures......450

Safety during electric welding......453

Safety when working on the machine's electrical system......455

Safety when handling accumulators......458

Safety when working on hydraulic systems......459

Safety when working on pressurized systems......461

Safety when handling oils and fuel......463

Starting with booster batteries......464

Safety when working with batteries......467

Rules when handling tyres......469

Safety when using lifting equipment......472

Safety when lifting and supporting the machine......474

Checking function......476

Service position 1......478

Safety when handling the machine......481

Safety concerns everybody!......486

FOPS and ROPS......488

CE-marking; EMC-directive......490

2 - ENGINE WITH MOUNTING AND EQUIPMENT......492

21 - ENGINE......493

Engine mounting rear; changing......494

Engine mount rubber cushion; replacing......498

Crankshaft; axial clearance; checking......502

Crankshaft rear oil seal; replacing......507

Crankshaft front oil seal; replacing......514

Camshaft; replacing......519

Camshaft setting; checking......536

Engine timing gear; description......541

Valve cover; installing......544

Valve cover; removing......549

Valves; adjusting_{07-04-12}......552

Valves; adjusting_{07-04-47}......563

Internal Exhaust Gas Recirculation (IEGR); description......574

Cylinder block; description......581

Crankcase ventilation; description......585

Cylinder head; description......588

Cylinder compression; testing......591

Engine; tightening torques......605

Engine rotation speed sensor (camshaft); replacing......616

Engine rotation speed sensor; replacing......621

Engine and transmission; installing......624

Engine and transmission; removing......645

Engine; specifications......668

22 - LUBRICATING SYSTEM......673

Lubrication pressure rocker arm shaft; checking......674

Lubrication oil pressure; checking with pressure gauge......679

Lubrication system; tightening torques......681

Lubrication system; component locations......685

Lubrication oil consumption; checking......688

Lubrication system; specifications......692

Lubrication system; description_{01-46-15}......694

Lubrication system; description_{01-47-43}......700

23 - FUEL SYSTEM......706

Injector sleeves; replacing......707

Overflow valve; replacing......715

Unit injector; replacing......719

Unit injector pretension; adjusting......731

Stall speed; checking......733

Fuel level; description......737

Fuel system; bleeding......739

Fuel pump; inspecting......742

Feed pump pressure; checking......759

Fuel system; component location......761

Carbon dioxide in fuel system; checking......763

Air in fuel system; checking......769

Fuel system; tightening torques......774

Fuel system; specifications......782

Fuel system; description......784

25 - INLET & EXHAUST SYSTEM......790

Cooling fan motor; charge air cooler; checking_adjusting high rpm......791

Cooling fan motor; charge air cooler; checking_adjusting low rpm......796

Charge air cooling system; description......801

Turbocharger; replacing......805

Turbocharger; inspecting......814

Exhaust pressure governor......819

Auxiliary brake (engine braking); description_{05-24-41}......822

Compression brake; description......825

Silencer; replacing......832

Inlet and exhaust system; tightening torques......843

Inlet and exhaust system; component location_{10-50-36}......849

Inlet and exhaust system; component location_{10-51-06}......851

Inlet and exhaust system; specification......853

Inlet and exhaust system; description_{10-52-54}......856

Inlet and exhaust system; description_{10-54-14}......861

Inlet and exhaust system; description_{10-55-36}......866

26 - COOLING SYSTEM......871

Cooling fan motor; radiator; checking high rpm......872

Cooling fan motor; radiator; checking_adjusting low rpm......876

Cooling fan speed control; description......881

Secondary coolant pump; replacing......885

Thermostat; secondary system; description......894

Radiator; adjusting......895

Cooling system pressure; checking......897

Cooling system; tightening torques......899

Cooling system; component location......902

Carbon dioxide in coolant system; checking......904

Cooling system; specification......910

Cooling system; description ......912

27 - ENGINE CONTROL......919

Electronic accelerator pedal; description......920

20 - GENERAL......922

E-ECU MID 128 non-programmed; replacing......923

E-ECU MID 128 pre-programmed; replacing......926

Engine; sensor locations......927

Engine; capacities......930

Tightening torques; engine mounts......931

Tech Tool; operations......933

Engine; description_{07-17-49}......935

3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......939

30 - GENERAL......940

SW8701; description and measuring......946

SW5901; description and measuring......948

SW5501; description and measuring......951

SW3801; description and measuring......954

SW3301; description and measuring......956

SWxxxx; Switches general; description and measuring......958

SE9504; description and measuring......960