Volvo A40 Articulated Dump Truck Repair Service Manual

Table of Content A40 Service Information

• GENERAL
  • DESCRIPTION, COMPLETE MACHINE
    • General
  • SPECIFICATIONS
    • • Product identification plates
  • STANDARD TIME
  • TOOL
    • • Drawings of E-tools that can be made in your own workshop

• STANDARD PARTS, SERVICE
  • LUBRICANT; FUEL; OTHER FLUID
  • SERVICE
    • Maintenance
      • Special instructions for servicing the electrical system
    • Emergency measures
    • Miscellaneous

• ENGINE WITH MOUNTING AND EQUIPMENT
  • • General, engine installation and its function
  • ENGINE
    • General, common info about 211 – 218
      • Compression check, engine at operating temperature
    • Valve mechanism
  • LUBRICATING SYSTEM
    • General, common info about 221 – 224
  • FUEL SYSTEM
    • General (common info about 233 – 238)
    • Fuel pump; filter; strainer
      • Fuel system, bleeding air
    • Injection pump; regulator; pump companion
      • Idle speed, checking and adjusting with service display unit
    • Injector; delivery pipe
  • INLET SYSTEM; EXHAUST SYSTEM
    • General, common info about 251 – 258
    • Exhaust brake
      • Exhaust retarder, functional description
      • Exhaust retarder, sensor, adjusting
      • Exhaust retarder, sensor, changing
  • COOLING SYSTEM
    • General, common info about 261 – 269
    • Radiator, mounting and connections included
      • Coolant, changing
    • Coolant pump; thermostat
      • Coolant pump, removed, reconditioning
    • Fan; fan shroud; fan coupling
      • Fan motor, checking operating pressure
      • Fan motor, changing, removing
    • Miscelaneous
      • Cooling system, functional diagram

• ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
  • • Comprehensive info, electrical system
  • BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
    • Battery
  • ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
    • Alternator inclusive drive
  • STARTING SYSTEM
    • Starter motor inclusive solenoid
    • Electric air pre-heater, excluding element
  • LIGHTING
    • Lighting, front, including parking light and day running light
    • Lighting, rear
    • Lighting, interior
    • Lighting, extra, including working lighting
  • OTHER ELECTRICAL EQUIPMENT
    • Direction indicator
  • CABLE; FUSE; RELAY
    • General, common info about 371 – 379
    • Electrical distribution box; fuse box; junction box
  • INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
    • General, common info about 383 – 387
      • Combination instrument
    • Speedometer; trip meter; hour counter
    • Sender, monitoring system
    • Warning/information unit, display unit

• POWER TRANSMISSION
  • • General, common info about 410 – 436
      • Missing signal from both engine speed sensor (SE3) and speed sensor (SE4)
  • CLUTCH; TORQUE CONVERTER
    • Hydrodynamic coupling, torque converter
  • TRANSMISSION, HYDRAULIC CONTROL
    • Transmission, hydraulic control
      • Checking main, torque converter and lubrication oil pressure
      • Checking modulating valves, retarder and lock-up
      • Measuring resistance in SE3, SE4 and SE86
      • Measuring resistance of sensor for retarder temperature (SE13)
      • Measuring resistance in cable harness
      • Multi-pin breaker box
      • Pressure regulator for retarder, checking and adjusting
      • Retarder valve, changing seal
      • Turbine speed sensor, changing
  • GEARBOX,
    • Distributing gearbox
      • Dropbox, changing seal for front output shaft
      • Longitudinal differential lock, adjusting engagement
  • PROPELLER SHAFT
    • General, common info about 451 – 453
    • Propeller shaft, complete
      • Propeller shaft for rear bogie axle, changing
      • Propeller shaft for front bogie axle, changing
  • FRONT AXLE; REAR AXLE
    • General, common info about 461 – 468
    • Front axle
    • Rear axle 1
    • Rear axle 2
    • Front axle, rear axle
      • Dog-clutch 6×6, checking and adjusting
    • Differential lock, with control
      • Transverse differential lock, adjusting engagement (per axle)
  • POWER TAKE OFF
    • Power take off
  • MISCELLANEOUS
    • General, common info about 491 – 492
      • Transmission PT 1760
      • Transmission, hydraulic diagram

• BRAKE
  • • Comprehensive info about brakes
  • WHEEL BRAKE
    • General, common info about 511 – 519
    • Front wheel brake (wet brake)
      • Brake discs, checking
      • Planetary gear with brake parts
  • HYDRAULIC BRAKE SYSTEM
    • General, common info about 520 – 522
      • Brake oil filter, changing
      • Brake system, bleeding air
      • Brake system, checking function
    • Brake cooling system
    • Brake valve
      • Foot brake valve (service brake valve), adjusting
      • Foot brake valve (service brake valve), changing
      • Valve slide position in valve housing, checking
    • Brake accumulator; hydraulic pump
      • Accumulator, checking
      • Hydraulic pump, changing
  • PARKING BRAKE
    • General, common info about 551 – 554
      • Spring brake cylinder, changing
    • Brake control, mechanical
      • Parking brake valve (hand-operated lever)
    • Propeller shaft brake
    • Wheel brake applying, parking
      • Load and dump brake (serial no. 1401Ţ€“, US 60301Ţ€“)
  • COMPRESSED-AIR BRAKE
    • General, common info about 561 – 565
    • Compressor; regulator; anti-freez unit
    • Compressed-air tank, with mounting
    • Valves, compressed-air
  • • General, common info about 591 – 594
      • Compressed air diagram
    • Retarder

• STEERING
  • • Comprehensive info, steering
  • • General, common info about 641 – 647
    • Steering gear
      • Steering gear, checking and adjusting
      • Steering, rack and pinion gear, changing
    • Steering arm; steering linkage; track rod
      • Steering linkage, changing roller bearing in rear lever (serial no. 1226Ţ€“, US 60146Ţ€“)
      • Steering linkage, changing roller bearing in bracket (serial no. 1226Ţ€“, US 60146Ţ€“)
      • Steering linkage, changing roller bearing in front lever (serial no. 1226Ţ€“, US 60146Ţ€“)
      • Steering linkage, checking and adjusting
      • Steering valve slide axial clearance, checking and adjusting
    • Hydraulic equipment
      • Steering cylinder, changing (right side)
      • Steering valve neutral position and valve slide axial clearance, checking
    • Steering damper
      • Damping cylinder, changing seals
      • Damping cylinder, checking pre-load

• FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
  • • Comprehensive info about frame and track unit/wheels
  • FRAME
    • General, common info about 711 – 718
      • Load unit frame, checking dimensions
  • SUSPENSION
    • General, common info about 725 – 727
    • Hollow rubber spring, bump stop
      • Removing and mounting
  • FRAME LINK
    • Bearings
      • Frame joint, changing metallic bearing
      • Frame joint, checking and adjusting clearance
    • Frame link grader
      • Steering joint, adjusting clearance
      • Steering joint, changing spherical bearings
  • AXLE SUSPENSION
    • General, common info about 751 – 758
    • Suspension, front axle
      • A-frame tractor unit, changing rubber bushing
    • Bogie suspension
      • Bogie beam, changing rubber bushing (one side)
      • Torsion bar, checking and adjusting
      • Torsion bar rubber bushing (rubber bearing), front, changing

• MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
  • CAB, NAKED; CANOPY
  • ENGINE HOOD; MUDGUARD; FOOT STEP
    • Engine hood with assembly parts
  • TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
    • Glass; sealing moulding
  • CAB INTERIOR/UPHOLSTERY
    • Driver’s seat, complete; instructor’s seat
      • If backrest adjustment is harsh or backrest is loose
      • OperatorŢ€™s seat, adjusting height of attachment
  • AIR CONDITIONING UNIT
    • General, common info about 872 – 877
    • Heating unit
      • Heat control valve, changing
      • Heater, changing
    • Cooling unit
      • Air conditioning, checking function
      • Air conditioning, functional description
      • Refrigerant, vacuum pumping including filling (charging)
  • INTERIOR EQUIPMENT
    • General, common info about 881 – 884
      • Protection against electromagnetic interference

• HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
  • WORKING HYDRAULICS; SERVO HYDRAULICS
    • General, common info about 911 – 917
      • Hydraulic system, bleeding air
    • Pump, working hydraulics
      • Hydraulic pumps for steering and dumping system, checking internal leakage
      • Oil pump, checking and adjusting hold pressure, pumps 1, 2 and 4
      • Oil pump, ground dependent, changing
    • Other hydraulic equipment
  • LOAD CARRIER
    • Hauler/platform body, incl. tipping cylinder; heating; tail gate
  • • General, common info about 992 – 996
      • Hydraulic diagram, brake system
      • Hydraulic diagram, complete