Volvo L40B Compact Wheel Loader Workshop Repair Service Manual PDF - MVLVCONL40B.zip

A full-service repair guide, complete with electrical wiring schematics, for the Volvo L40B Compact Wheel Loaders — containing every technical detail needed to service, troubleshoot, overhaul, and rebuild the machine the way trained technicians do.

The workshop service and repair manual for Volvo Construction's L40B Compact Wheel Loaders 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.

Volvo L40B Compact Wheel Loaders Service Repair Manual.pdf

PRODUCT DETAILS:

Total Pages: 619

File Format: PDF (Windows & Mac & Linux)

Language: English

CONTENTS

000 - Foreword............2

000 - GENERAL............3

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

Description............5

03 - SPECIFICATIONS............6

Volvo standard tightening torques............7

Conversion tables............10

Engine; specifications............18

Engine; weights............20

Engine; capacity............21

Engine; tightening torque............22

Cooling system; capacity............24

Air conditioning (option); capacity............25

Electrical system; specifications............26

Battery; specifications............27

Power transmission; specifications............28

Front axle; specification............29

Front axle; weight............30

Front axle; capacity............31

Rear axle; specification............32

Rear axle; weight............33

Rear axle; capacity............34

Axles; tightening torques............35

Brakes; specifications............36

Hydraulic system; specification............37

Frame; weight............38

Counterweight; tightening torques............39

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION............41

Machine; transporting............42

07 - STANDARD TIME............44

Operation numbers for additional work............45

08 - TOOL............47

E-tool Cab support............48

001 - STANDARD PARTS; SERVICE............49

16 - LUBRICANT; FUEL; OTHER FLUID............50

Lubricant recommendation............51

Alternative fuels............53

17 - SERVICE............56

Environmental concern............57

Work on the machine's electrical system............58

Cleanliness; braking and hydraulic system............59

Electric welding ............60

Arrival Inspection; according to Inspection Programme............61

Delivery Inspection; according to Inspection Programme............62

Delivery Instructions; according to Inspection Programme............63

Maintenance of Stored Machines; according to Inspection Programme............64

Service Programme............65

Service positions ............66

Service intervals............67

Engine; changing oil and filter............69

Coolant; changing............71

Axles; changing oil............73

Hydraulic oil tank; changing oil and filter............76

Towing............78

19 - GENERAL............79

Safety concerns everybody!............80

CE-marking; EMC-directive............82

Service positions............86

Safety during work on machines............87

Safety rules when servicing............91

Safety when raising and jacking up the machine............94

Loader boom; safety strut............96

Fire prevention measures............99

Some simple rules regarding tyre handling............103

Checklist after a fire or heat exposure............105

Health hazards with paint; plastics and rubber............106

Safety when handling oils and fuel............108

Safety when working with air conditioning refrigerant............110

Environmental handling for the future............112

Waste handling............114

Environmentally safe handling............118

Environmentally hazardous fluids............121

Safety when working with refrigerant............124

Working in environmentally contaminated areas............127

Decontamination............130

002 - ENGINE WITH MOUNTING AND EQUIPMENT............134

20 - GENERAL............135

Engine; description............136

Engine; weights............139

Engine; weight............140

Engine; capacity ............141

Engine; tightening torque ............142

Engine; capacity-............144

Engine; tightening torque............145

21 - ENGINE............147

Engine; specifications............148

Cylinder compression; testing............150

Engine; capacity............152

Cylinder head; description............153

Valves; description............155

Valves; adjusting_{008-23-55}............157

Valves; adjusting_{008-23-28}............162

Engine timing gear; description............166

Camshaft; description............167

Crankshaft; description............168

Connecting rod; description............169

22 - LUBRICATING SYSTEM............171

Lubrication system; description............172

Oil pump; description............174

Oil cooler; replacing............175

23 - FUEL SYSTEM............179

Fuel system; description............180

Fuel feed pump; description............182

Feed pump; replacing............183

Fuel filters; replacing............187

Injection valve; check............189

25 - INLET & EXHAUST SYSTEM............192

Turbocharger; description............193

Air cleaner; description............195

26 - COOLING SYSTEM............196

Cooling system; description............197

Cooling system; capacity............198

Coolant pump; replacing............199

Thermostat; replacing............202

Maximum fan speed; checking............204

003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS............207

30 - GENERAL............208

Electrical system; instructions............209

Electric welding............210

Electrical system; description............211

Electronic unit (ECU)_{008-07-14}............213

Electronic unit (ECU)_{008-06-52}............215

Electrical system; specifications............217

31 - BATTERY............218

Battery; description............219

Battery; specifications-............220

Battery; specifications............221

Battery; charging............222

33 - STARTING SYSTEM............224

Starter lock; replacing............225

35 - LIGHTING............227

Lighting; specifications............228

36 - OTHER ELECTRICAL EQUIPMENT............229

Combination control (by steering wheel); changing............230

Windscreen wiper front motor; replacing............232

Connectors; overview_{008-00-31}............236

Connectors; overview_{008-00-11}............248

37 - CABLE; FUSE; RELAY............256

Cable markings............257

Component list; relays............259

Electronic unit (ECU); fuse position_{007-57-34}............261

Electronic unit (ECU); fuse position_{007-57-15}............264

Connector I_O description............266

Wiring diagram; figure text............268

Wiring diagram 001............277

Wiring diagram 002............283

Wiring diagram 003............289

Wiring diagram 004............291

Wiring diagram 005............293

Wiring diagram 006............296

Wiring diagram 007............298

Wiring diagram 008............300

Wiring diagram 009............302

Wiring diagram 010............304

Wiring diagram 011............309

Wiring diagram 012............316

Wiring diagram 013............318

Wiring diagram 014............321

Wiring diagram 015............323

Wiring diagram 016............327

Wiring diagram 017............330

Wiring diagram 018............332

Wiring diagram 019............335

Wiring diagram 025............338

38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM............340

Electric cables with component marking............341

Display of bar graph............353

ECU 002; functions............355

ECU 002; error codes and diagnostic functions............376

IB - fuse F002............386

Pro FET-components in electronic unit (ECU)............387

Relays and fuses in engine compartment............390

Central ground connections_{007-41-40}............392

Central ground connections_{007-41-19}............394

Electrical components; engine side............396

Instrument panel; description_{007-40-15}............398

Instrument panel; description_{007-39-53}............400

Keypad; description............402

Display unit and keyboard............403

Instrument panel (display unit); replacing............405

Key pad; replacing............409

004 - POWER TRANSMISSION............411

40 - GENERAL............412

Power transmission; description............413

44 - HYDROSTATIC DRIVE............416

Power transmission; specifications ............417

Transmission; component location............418

Hydraulic diagram transmission............421

Check and adjust hydrostatic drive............426

Power transmission; specifications............438

Hydrostatic motor; removal_{007-31-43}............439

Hydrostatic motor; removal_{007-31-21}............440

Hydrostatic motor; installation_{007-30-50}............441

Hydrostatic motor; installation_{007-30-31}............443

Assembling the hydraulic motor............445

Hydrostatic pump; removing and installing............448

46 - FRONT AXLE; REAR AXLE............450

Front axle; specification ............451

Front axle; weight ............452

Front axle; capacity-............453

Rear axle; specification-............454

Rear axle; weight-............455

Rear axle; capacity-............456

Axles; tightening torques-............457

Front axle; specification............458

Front axle; weight-............459

Front axle; capacity............460

Rear axle; specification............461

Rear axle; weight............462

Rear axle; capacity............463

Axles; tightening torques............464

005 - BRAKE............465

50 - GENERAL............466

Brake; description............467

Service brake; specifications............468

Brake system; component............469

Hydraulic diagram; brake system; dry brakes............471

Hydraulic diagram; brake system; wet brakes............474

51 - WHEEL BRAKE............477

Brake linings; checking wear............478

Brake calliper removed; reconditioning............481

52 - HYDRAULIC BRAKE SYSTEM............483

Brake system hydraulic function; checking............484

Accumulator; checking (removed)............487

Accumulators; checking in machine............489

55 - PARKING BRAKE............490

Brake disc; replacing one............491

006 - STEERING............493

60 - GENERAL............494

Steering system; specifications-............495

Steering system; description............496

Steering system; specifications............498

Steering; hydraulic equipment; tightening torques............499

Steering; tightening torques............500

64 - STEERING............501

Steering system; troubleshooting and elimination............502

Hydraulic diagram; steering system............505

Steering system working pressure; checking and adjusting............507

Steering valve; reconditioning (removed)............509

007 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT............517

70 - GENERAL............518

Frame and track unit; description............519

Frame; weight-............521

Frame; weight -............522

Frame; weight.............523

Frame; weight............524

71 - FRAME............525

Counterweight; tightening torques............526

Damper weight; weight............528

74 - FRAME LINK............529

Frame and steering joint; general............530

Steering joint; tightening torques............532

Frame joint; changing bearings............534

77 - WHEELS; TRACKS; TYRE; HUB; DRUM............537

Tire size............538

Wheel; tightening torque............539

Front axle; weight............540

008 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE............541

80 - GENERAL............542

Cab description............543

Cab mounts; tightening torques............544

81 - CAB; NAKED; CANOPY............546

Repairs of minor damage on internal and external plastic parts (scratches; dents; breaks)............547

Cab mounts; tightening torques............549

84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING............551

Windows; general............552

Windscreen; replacing............553

Rear window; replacing............556

Door window; replacing............559

87 - AIR CONDITIONING UNIT............563

Air conditioning (option); capacity............564

009 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS............565

90 - GENERAL............566

Cleanliness when working on hydraulic components............567

Hydraulic system; position of main components............568

Hydraulic diagram; working hydraulic system............570

Hydraulic diagram; Boom Suspension System............573

Hydraulic diagram; control valve............575

General information to note when working on the hydraulic system............578

Hydraulic oil; storage and handling............580

Hydraulic system; repair of hydraulic components in workshop............581

Hydraulic components; storing and transporting............583

Troubleshooting chart............584

Discarded accumulators............587