Volvo A40D Articulated Hauler Workshop Repair Manual PDF - MVOLCOA40D.zip

A full-service repair manual featuring Electrical Wiring Diagrams for the Volvo A40D Articulated Hauler, packed with the shop-level detail needed to service, troubleshoot, fix, and rebuild the machine just like the pros do.

The Volvo A40D articulated hauler workshop service and repair manual 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.

Articulated Haulers A40D Volvo Service Repair Manual.pdf

MAIN SECTIONS

0 - GENERAL

1 - STANDARD PARTS, SERVICE

2 - ENGINE WITH MOUNTING AND EQUIPMENT

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

4 - POWER TRANSMISSION

5 - BRAKE

6 - STEERING

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

8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE

9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM

PRODUCT DETAILS:

Total Pages: 3,912

File Format: PDF (Windows & Mac & Linux)

Language: English

TABLE OF CONTENTS

000 - GENERAL........2

00 - DESCRIPTION; COMPLETE MACHINE........3

Hydraulics........4

Product identification plates........6

Information and warning decals........8

Steering cylinder; description........11

03 - SPECIFICATIONS........16

Tightening torques........17

Dimensions for A035D with 26.5 R-25 tyres........28

Dimensional diagram A040D........30

Dimensions for A040D with 29.5 R-25 tyres........32

Weights; A040D........34

Capacities; A040D........35

Rocker arm shaft; tightening torques........36

Tightening torques; valve cover........38

Coolant with freezing and corrosion protection........39

Power take-off; tightening torque........40

Tyre equipment and recommended tyre pressures........42

Fuel system; specifications........44

Conversion tables........45

Lubrication system; specifications........50

05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION........51

Recovering and towing........52

Lifting machine; A035D........54

Lifting machine; A040D........59

Dealers_retrofitter´s responsibility........64

Appointment and distribution of responsibility........65

07 - STANDARD TIME........66

Operation numbers for additional work........67

08 - TOOL........69

E-1750........70

E-1763........71

E-2000........73

E-2502........75

E-2516........77

E-2519........78

88830051 User Instruction........80

09 - MISCELLANEOUS........90

Troubleshooting; general........91

Troubleshooting strategy........92

Troubleshooting; assistant devices........95

Collection of basic data........96

VCADS Pro service tool; general........99

VCADS Pro; Test........101

VCADS Pro; Error codes........103

VCADS Pro; Calibrating........105

VCADS Pro; Programming........107

VCADS Pro tests........110

Basic checks........114

Engine; basic check........116

Electrical system; basic check........120

Power transmission; basic check........124

Basic check; transmission........126

Brake system; basic check........127

Parking brake; basic check........130

Steering and hydraulics; basic check........132

001 - STANDARD PARTS; SERVICE........134

11 - STANDARD PARTS........135

Service........136

16 - LUBRICANT; FUEL; OTHER FLUID........137

Recommended lubricants........138

Lubrication and service schedules........140

Alternative fuels........141

17 - SERVICE........144

Safety when servicing........145

Warranty inspection........147

Warranty inspection 100 hours........148

Warranty inspection 1000 hours_{09-06-18}........150

Warranty inspection 1000 hours_{09-05-58}........153

Maintenance service; daily........156

Maintenance service; every 050 hours........158

Maintenance service; every 250 hours........161

Maintenance service; every 500 hours........167

Maintenance service; every 1000 hours........181

Maintenance service; every 2000 hours........210

Condition test and maintenance program........256

Lubrication; see lubrication chart........258

Service journal (included in Operator's manual); fill in........259

Coolant; Changing........260

Recovering and towing-........265

Dump body alternative; lowering........267

Mechanical release of parking brake........270

Transporting the machine........272

19 - GENERAL........274

Cleanliness; brake and hydraulic systems........275

Refrigerant for air conditioning........276

CE-marking; EMC-directive........277

Safety concerns everybody!........281

Safety when handling the machine........285

Service position 001........289

Safety when lifting and supporting the machine........291

Safety when using lifting equipment........293

Rules when handling tyres........295

Safety when working with batteries........298

Starting with booster batteries........300

Safety when handling oils and fuel........301

Safety when working on pressurized systems........302

Safety when working on hydraulic systems........304

Safety when handling accumulators_{008-46-17}........306

Safety when handling accumulators_{008-45-55}........307

Safety when working on the machine's electrical system........308

Safety during electric welding........309

Fire prevention measures........310

Checklist after a fire or heat exposure........313

Health hazards with paint; plastics and rubber........316

Environment........319

Environmental handling for the future........321

Waste handling........323

Environmentally safe handling........327

Environmentally hazardous fluids........329

Safety when working with air conditioning refrigerant........332

Working in environmentally contaminated areas........335

Decontamination........338

002 - ENGINE WITH MOUNTING AND EQUIPMENT........342

20 - GENERAL........343

Tightening torques; engine mounts_{008-38-13}........344

Tightening torques; engine mounts_{008-37-51}........346

Engine control unit D012; E–ECU; description of function........348

E–ECU D012; Functions........351

E–ECU D012D; Input and Output terminals........355

Engine D012; description........357

Engine; fill quantities........359

Engine; identification........360

E-ECU MID 128 pre-programmed; replacing_{08-34-15}........362

E-ECU MID 128 pre-programmed; replacing_{08-33-57}........364

E-ECU MID 128 non-programmed; replacing_{08-33-26}........366

E-ECU; changing_{008-33-04}........369

21 - ENGINE........375

Engine; general specifications........377

Cylinder compression; PC test........380

Engine; removing........381

Engine; installing........402

Engine and transmission; removing........419

Engine and transmission; installing........441

Engine speed sensor; changing........458

Engine rotation speed sensor (camshaft); replacing........466

Cylinder compression; testing........473

Tightening torques; valve cover-........482

Tightening torque; cylinder head........483

Cylinder head; description........484

Cylinder block; description........486

Cylinder liner; description........489

Pistons; description........491

Valve mechanism; double rocker arm_{008-20-57}........492

Valve mechanism; specifications_{008-20-35}........494

Valve mechanism; double rocker arm_{008-20-07}........496

Valve mechanism; specifications_{008-19-45}........498

Valve mechanism; description........500

Adjusting; general........503

Internal Exhaust Gas Recirculation (IEGR); description........505

Valves; adjusting_{008-17-12}........511

Valves; adjusting_{008-16-48}........518

Valves; adjusting_{008-16-26}........522

Engine transmission; specification........530

Engine timing gear; description........533

Camshaft; description........535

Camshaft setting; checking........536

Camshaft; replacing........546

Timing gear case new gasket; installing........565

Camshaft; checking........576

Crank mechanism; description........581

Flywheel; tightening torques........583

Crankshaft rear oil seal; replacing........584

Oil sump; tightening torque........591

Oil level sensor; replacing........593

Oil sump gasket; replacing........600

Engine mount rubber cushion; replacing........607

Engine mounting rear; changing........611

22 - LUBRICATING SYSTEM........615

Lubrication system; description_{008-03-52}........616

Lubrication system; description_{008-03-33}........617

Function of the valves........618

Lubrication system; principle........620

Oil pump and oil cooler........622

Lubrication oil pressure; checking with pressure gauge........623

Oil cooler; tightening torques........625

Oil cooler; replacing........628

23 - FUEL SYSTEM........632

Fuel system; specifications ........634

Fuel system; tightening torques........635

Instructions for working with electronic fuel injection........636

Fuel system; description........637

Fuel flow; description........640

Fuel system's components........643

Fuel flow D012C........645

Checking stalling speed-........647

Air in fuel system; checking........650

Cylinder balancing; PC test........654

Carbon dioxide in fuel system; checking........655

Fuel feed pump; specifications........661

Fuel feed pump; description........662

Feed pump pressure; checking........664

Fuel filter housing; description........666

Fuel pump; inspecting........669

Fuel pump (valves); inspecting........674

Fuel system; bleeding_{007-51-25}........676

Fuel system; bleeding_{007-51-03}........678

Feed pressure; PC test........681

Fuel filter; description........682

Water trap; description........684

Filter head D012D; description........685

Checking stalling speed........688

Unit injectors; specifications........691

Unit injector; Bosch; description........692

Unit injector; Delphi; description........694

Function of unit injectors........697

Unit injector; adjusting pretension........702

Unit injector; replacing........705

Injector shut off; manual........714

Overflow valve; checking........715

Injector sleeves; replacing........718

25 - INLET & EXHAUST SYSTEM........726

Air intake and filter........727

Charge-air cooling........728

Preheating coil........729

VEB; description........730

Rocker arm piston; D12C........736

VEB; activation........738

Exhaust pressure governor........740

Turbocharger; specifications........741

Turbocharger........742

Turbocharger; overview illustration........743

Turbocharger; inspecting........745

Turbocharger; replacing........748

Air cleaner; preheating coil; specifications........753

Air cleaner; description........754

Preheating coil; replacing........755

Intercooler; specifications........758

Intercooler; description........759

Charge air cooler; replacing........760

Cooling fan motor; charge air cooler; checking_adjusting low rpm........768

Cooling fan motor; charge air cooler; checking_adjusting high rpm........772

Hydraulic cooling fan control; PC test-........776

26 - COOLING SYSTEM........777

Cooling system; tightening torques........778

Description........780

Cooling system; principle illustrations........782

Coolant circulation; description........784

Cooling system; flushing........786

Cooling system specifications........791

Radiator; description........793

Radiator; removing_{07-29-53}........794

Radiator; removing_{07-29-32}........801

Radiator; installing_{07-28-58}........809

Radiator; mounting_{07-28-36}........816

Coolant filter; changing........824

Radiator; adjusting........827

Coolant; changing........829

Thermostat; description........834

Coolant pump; description........836

Thermostat; primary system........838

Thermostat; primary system; description........839

Thermostat; secondary system........841

Thermostat; secondary system; description........842

Coolant pump; reconditioning........843

Fan system; description........850

Fan belt and_or alternator belt; checking and adjusting tension_{07-23-26}........851

Fan belt and_or alternator belt; checking and adjusting tension_{07-23-04}........854

Cooling fan motor; radiator; checking_adjusting low rpm........856

Cooling fan motor; radiator; checking_adjusting high rpm........860

Hydraulic cooling fan control; PC test........864

003 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS........865

30 - GENERAL........866

Electrical system; special instructions for servicing; electronic components........889

Electrical system; special instructions for servicing; electrical components; batteries........892

Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{02-03-11}........894

Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{02-02-41}........896

Electrical system; special instructions for servicing; action when working on machine........898

Data buses; function........900

Service connection and programming connection........902

Software versions and ECUs_part number; general........904

Software versions and ECUs_part number; checking........906

Software versions and ECUs_part number; list........909