Service Information Document Title: Brake system, basic check
Function Group: 090
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
Brake system, basic check Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999
WARNING Certain tests are performed with the parking brake released. Make sure that the machine does not start to roll when the parking brake is released. Basic check, purpose The purpose of the basic check is to give quick and reliable information about the system general health. The normal procedure is that after collecting basic information, reading faultcodes and parameter control perform the basic check (if the fault hasn't been previously determined). Checklist before basic check Before the basic check is executed it should be ruled out that the problems don't occur depending on any certain elementary faults. Therefore always check: Checking
Explanation
Warning
Low accumulator pressure Axles, high brake cooling oil temperature Hydraulic oil, low level in tank Brake cooling, critical cooling oil level in tank
Fluid levels
Hydraulic oil Brake cooling oil
Op nbr 090-003 Basic check This operation also includes required tools and times for applicable parts of the following operations: Service positions Load and Dump brake function, checking 1. Check for any abnormal noise and vibrations from hydraulic pump number 6.
Figure 1 Pump position 1 Steering / dumping 2 Steering / dumping 3 Steering / dumping 5 Intercooler (charge-air cooler) 6 Brake / cooling fan pump 7 FS-pump (Only applies to FS-machines) Also check for any abnormal noise and vibrations from the brake pedal, valves, and wheel brake. See also Steering and hydraulics, basic check. 2. Check that the brakes engage evenly when braking. 3. Check that the machine does not pull to the right or left when operating. 4. Operate the machine and then check if any hub is hotter or colder than the others. 5. Place the machine in service position, see Service positions. 6. Activate the service mode function in the information display unit to be able to read out accumulator brake pressure in bar. See Service mode, description. 7. Start the engine and make sure that there is full brake pressure in the accumulators. See Hydraulic pressure, specifications. Turn off the engine with the safety stop and check in the information display unit that the accumulator brake pressure does not drop, which may indicate a leak. 8. Start the engine and make sure that there is full brake pressure in the accumulators. See Hydraulic pressure, specifications. Turn off the engine with the safety stop, press down the brake pedal, and check in the information display unit that the brake pressure does not drop, which may indicate a leak. 9. Start the engine, press down the foot brake, deactivate the parking brake, move the gear selector to position D and activate the load and dump brake, release the foot brake. Check in the information display unit that the brake pressure does not drop, which may indicate a leak. Also check the function of the load and dump brake, see Load and Dump brake function, checking. 10. Release the accumulator pressure in the brake system as follows: Stop the engine with the safety stop and press down the brake repeatedly until the oil flow through the foot brake valve stops, that is, until the 'hissing' sound has stopped and the pedal feels "spongy". Check in the information display unit's service mode that the accumulator brake pressure has dropped to <3bar. 11. Start the engine at low idle, move the gear selector to position D without activating the parking brake. Observe the pressure build-up on the information display unit. The brake pressures in both circuits should follow each other until full brake pressure is reached, see table below.
The low brake pressure alarm should be deactivated as indicated in the table. Alarm deactivated
Full brake pressure
after approx. 6 seconds
after approx. 12 seconds
after approx. 6 seconds
after approx. 12 seconds
The charging time may not deviate too much from the stated times.
Figure 2 Warning low accumulator pressure
Figure 3 Brake pressure tractor
Figure 4 Brake pressure trailer
12. Start the engine and make sure that the accumulators have full brake pressure. Release the parking brake, stop the engine with the safety stop and press the brake pedal all the way down twice. This must be possible without the parking brake being activated.
Figure 5 Indicator light, parking brake applied 13. Activation of the parking brake indicates a malfunction in the brake system. 14. Start the engine and make sure that there is full brake pressure in the accumulators. Check the accumulator brake pressure in the information display unit's service mode. Brake lightly with the brake pedal until brake charging is activated and starts to build up the pressure again, until brake charging is deactivated, see correct value for each machine model. See Hydraulic pressure, specifications. The time between these two pressures should be between 1–2 seconds.
Service Information Document Title: E-1763
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-1763 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 E1763, Drain hose
Figure 1 E1763 1. 2. 3. 4. 5.
4880194 Quick coupler 948883 Seal ring 4786606 Nipple 13943472 Hose clip 13946652 Hose
NOTE! All included parts can be ordered as spare part from Volvo CE.
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Service Information Document Title: E-2000
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2000 Showing Selected Profile Valid for serial numbers Model A40F Volvo SN 11001-99999
Figure 1
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Service Information Document Title: E-2517
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2517 Showing Selected Profile Valid for serial numbers Model A40F Volvo SN 11001-99999 Shut-off valve
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Figure 1 Shut-off valve Pos.
Part no.
Pos.
Part no.
Pos.
Part no.
1
9993758
5
13933936
9
14013067
2
14013067
6
935027
10
14371522
3
935027
7
936439
11
936771
4
936771
8
11705447
12
2–way ball connection
valve
G
1/4"
Service Information Document Title: E-2518
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2518 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Adapter
Figure 1 Adapter 1. 2. 3.
Part no. 9993758 Part no. 14013067 Part no. 935027
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Service Information Document Title: E-2519
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2519 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Measuring nipple
Figure 1 V1083149 1. 2. 3.
15018967 Testing nipple 948883 Gasket 88830130 Nipple
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Service Information Document Title: E-2525
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2525 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 E-2525 Adapter, checking oil pressure in rocker arm shaft
Figure 1 Adapter 1. 2. 3.
11701845 Connection 11701850 Adapter 936440 Testing nipple
For D11, all three parts are used. For D13 and D16, only pos. 2 and 3 are used.
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Service Information Document Title: E-2526
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2526 Showing Selected Profile Valid for serial numbers Model A40F Volvo SN 11001-99999 Puller Dimensions in millimetres (mm)
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Figure 1 Puller 1. 2. 3.
Nut plate Flat bar Material S355JO Fork ear Flat bar Material S355JO Screw M16x100 which is cut to 50
Service Information Document Title: E-2529
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2529 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Adapter
Figure 1 V1130400 1. 2. 3.
Part no. 9993758 Part no. 14013067 Part no. 935026
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Service Information Document Title: E-2546
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
E-2546 Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Dragbult för att pressa på lager. Svetsad mutter på skruv: – Fasa av kanterna (e) lite grann på skruvens skalle. Skjut in skruvens skalle (k) i muttern, svetsa därefter på undersidan av skruvens skalle. M10 Bult
mm d1 = 10 bL = 26 e = 18,9 k = 6,4 s = 17 Nyckelvidd enligt DIN 931 / 933
M20 Mutter
mm e = 32,95 s = 30 m = 18
Figure 1 V1184042
Figure 2 V1184041
Figure 3 V1077215 1. 2.
M10 Bult M20 Mutter
Svetsfog illustration
Figure 4 V1184095
Service Information Document Title: Electrical system, check
Function Group: basic 090
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
Electrical system, basic check Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Basic check, purpose The purpose of the basic check is to give quick and reliable information about the system general health. The normal procedure is that after collecting basic information, reading faultcodes and parameter control perform the basic check (if the fault hasn't been previously determined). Checklist before basic check Before the basic check is executed it should be ruled out that the problems don't occur depending on any certain elementary faults. Therefore always check: Checking
Explanation
Reference
Fuses
Check that all fuses are intact
Electrical distribution box, description
Engine stop, internal Engine stop (optional equipment)
Shall not be activated (pressed in)
Alternator
Checking belts and belt tension
Electrical system, special instructions for servicing, general
Op nbr 090-002 Basic check This operation also includes required tools and times for applicable parts of the following operations: Service positions 1. Place the machine in service position, see Service positions. NOTE! Check that the battery disconnect switch is in the position that cuts off the main current. 2.
ode plates.
3. Check the batteries' electric connections. 4. Switch on the main current with the battery disconnect switch. 5. Check that the electrical system powers up (is supplied with voltage) and that start figure with machine hours is shown in the information display unit.
Figure 1 Machine hours 6. Turn the ignition to position 1. The control light test is run at the same time as a rotating Volvo logo is shown in the information display unit. NOTE! If the machine is equipped with theft protection, the display figure for entering the code is shown.
Figure 2 Volvo logotype 7. Check that the electronics start and that the operating display is shown. The operating display that is shown is the same as when the electronics were shut down. The charging light (battery symbol) should be on constantly with a red light.
Figure 3 Operating display 1, shown as default 8. Check that the system voltage is above 24 V by entering service mode and selecting "5 Electrical system". See Service
mode, description.
Figure 4 System voltage 9. Activate headlights, high beams and flashing hazard lights. Walk around the machine and check that the lights are on/ flash. Restore. 10. Activate and check interior lighting. Restore. 11. Activate and check the ventilation fan. Restore. 12. Activate the floor switch for differential locks (all) and check that the control lights are on. Restore.
Figure 5
1.
Control lights differential locks
13. Start the engine. Check that: The preheating symbol in the operating display first turns on and then turns off The charging light turns off
Figure 6
1. 14.
Symbol for preheating
Service mode, description.
cal system". See
Figure 7 System voltage 15. Run up the load body. Then lower the load body by moving the dump lever to lowering position with hold function. Check that the dump lever remains in hold position (hold solenoid) until the load body is down. When the body is down, the dump lever returns to float position. NOTE! When lowering, check that the dump lever goes to float position when any of the following occurs: Ignition is turned to position 0 The operator stands up 16. Activate the load and dump brake and check that the symbols for the load and dump brake as well as service brake turn on. Reset by moving the gear selector from neutral position.
Figure 8
Symbol for load and dump brake (amber)
Figure 9 Symbol for service brake (green) 17. NOTE! Only applies to A35F FS/A40F FS Set the switch for the FS-system in normal position by pressing in the upper part of the switch. Check that the machine is being adjusted and that the operating display shows yellow arrows and spring. The arrows should flash at the same rate. When normal position has been reached, check that the operating display shows green arrows and spring for approx. 10 seconds. Then the arrows and spring should disappear from the operating display.
Figure 10 Switch for FS-system
Figure 11 Adjusting towards normal position (yellow arrows and spring) and normal position reached (green arrows and spring) 18. NOTE! Only applies to A35F FS/A40F FS Set the switch for the FS-system in bottom position by pressing in the lower part of the switch. To change the switch, the red lock device has to be slid down. Check that the machine is being adjusted and that the operating display shows yellow arrow and spring. The arrow
under the spring flashes. When bottom position has been reached, check that the operating display shows green arrow and spring.
Figure 12 Adjusting towards bottom position (yellow arrow and spring) 19. Activate internal engine stop (internal emergency stop switch). Check that the engine stops. Reset the internal engine stop by turning the switch clockwise so that it pops out.
Figure 13
1.
Emergency stop switch
20. NOTE! Only applies if extra emergency stop switch is installed. Start the engine. Activate external engine stop (external emergency stop switch). Check that the engine stops. Reset the external engine stop by turning the switch clockwise so that it pops out.
Figure 14
1.
Extra emergency stop switch on left front fender (optional equipment)
21. Turn the ignition to position 0. 22. Turn off the main electric power with the battery disconnector.
Service Information Document Title: Engine, basic check
Function Group: 090
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
Engine, basic check Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999
WARNING Certain tests are performed with the parking brake released. Make sure that the machine does not start to roll when the parking brake is released. Basic check, purpose The purpose of the basic check is to give quick and reliable information about the system general health. The normal procedure is that after collecting basic information, reading faultcodes and parameter control perform the basic check (if the fault hasn't been previously determined). Checklist before basic check Before the basic check is executed it should be ruled out that the problems don't occur depending on any certain elementary faults. Therefore always check: Checking
Explanation
Reference
Fuses
FU71/72, F70
Wiring diagram WD304
FU17, FU23, FU24, FU30, FU31, FU40
Electrical distribution box, description
Fuel
Level
Engine stop, internal Engine stop equipment)
(optional
May not be pressed in
Gearshift selector
Shall be in position N
Battery voltage
Shall be over 24 V
Engine
Visual check of hoses, connections, cable harnesses and components.
Op nbr 090-001 Total procedure time (hr): 0.70 Basic check This operation also includes required tools and times for applicable parts of the following operations: Service positions Engine off
1. Place the machine in service position, see Service positions. 2. Place the battery disconnector in position on and the start key in position 1. 3. Select "Service mode" in the information display unit. See: Service mode, description. 4. Check the coolant temperature. If the engine is cold, the coolant temperature should be the same as the ambient temperature. If the engine is at operating temperature, the coolant temperature should be 77–95 °C and the same as shown by the temperature gauge in the information display unit. Coolant temperature ° /°
5. Check the coolant level. It should be over the MIN level. This is indicated by a symbol in the information display unit. Compare to the actual coolant level. Coolant level XXXX
6. Check the engine oil level. It shall be between MAX and MIN lines on the oil dipstick.
Figure 1 Oil dipstick 7. Check the engine oil temperature. If the engine is cold, the engine oil temperature should be the same as the ambient temperature. If the engine is at operating temperature, the temperature should be 0–10 ºC below the coolant temperature. At abnormal temperature, troubleshoot the sensor and the cable harness. Engine oil temperature ° /°
Engine running
8. Start the engine. 9. Check that there are no alarms related to the engine, see: Information display, vehicle messages. 10. Run the engine to operating temperature (77–95 ºC). 11. Check that the engine responds to throttle application. 12. Check the pressure-drop indicator. It shall indicate "clogged air filter" if the vacuum pressure after the filter is too high. Check the sensor by covering the air inlet before the filter housing with a stiff board that cannot be sucked in. The air supply before the filter is restricted and the sensor should now indicate "clogged air filter". Air filter XXXX
13. Check the coolant temperature. If the engine is at operating temperature, the coolant temperature should be between 77–95 ºC and the same as shown by the temperature gauge in the information display unit. If the engine is cold, the coolant temperature should be the same as the ambient temperature. Coolant temperature ° /°
14. Check the coolant level. It should be above the MIN level. Check if the level in the expansion tank has dropped after start. Coolant level XXXX
15. Check the engine oil temperature. At normal operating temperature, it should be approx. 0–10 ºC below the coolant temperature. Engine oil temperature ° /°
16. Check the engine oil pressure in the information display unit. Engine oil pressure
17. Check the engine speed. It shall match the tachometer. Check also that the values for low and high idle match the engine's specifications (parameters).
Engine speed
Figure 2 Tachometer 18. Check that there is no noise or leakage.
Service Information Document Title: Infrared Thermometer
Function Group: 080
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
Infrared Thermometer Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999 Gun Style Infrared Thermometer Laser Sight Model: SIG1 9998519Infrared thermometer (user instruction in FGI 080)Application This tool can be used to measure fast and easy temperature differences. For instance in case of troubleshooting it is sometimes necessary to measure temperature differences on two equal parts with the same surface.
WARNING Never point the device towards the eyes permanent eye damage may occur. Use extreme caution when using the laser. Keep out of the reach of children. Be careful around mirror surfaces since mirrors can reflect the laser. Looking into the reflected laser is just as damaging as looking directly at the laser. General information 1.
2.
3.
Field of view: The SIG1 takes it’s measurement from a circle of a size determined by a simple ratio of 10:1. The diameter of this circle is 1/10 the distance between the target and the tip of the SIG1. For example, if you’re standing 20 feet (610 cm) from your target, the size of the circle you’re taking the average temperature of will be 2 feet (61 cm) wide. If you want to get the temperature of something small, such as a pipe, you must get close enough for the pipe to take up the whole viewing area circle. Otherwise the pipe and the background temperatures will be averaged into the reading. You need to be aware that if the target surface is reflective enough, it may reflect infrared from other objects. For example, if you take a reading of a shiny metal surface, the infrared energy of your face may reflect enough energy off the surface to affect the reading. For this reason, it’s a good idea to put non-reflective tape or paint on reflective surfaces when taking infrared temperature readings.
NOTE! The measured temperature will be lower than actual. Operation 1. 2. 3. 4. 5.
Point the laser towards the target to be measured. Pull trigger to light the target with the laser and measure its surface temperature. As long as the trigger is held down, the SIG1 will constantly update the measurement and the blue backlight will illuminate the display. When the trigger is pulled the red laser dot will shine about 1/4” above the centre of the circular area being measured by the thermometer. Once the trigger is released, the last measurement will be shown and held until the trigger is pressed again or until the SIG1 turns off.
Service Information Document Title: Operation numbers additional work
Function G roup: for 070
Information Type: Service Information
Date: 3/26/2020
Profile: Articulated Haulers
Operation numbers for additional work Showing Selected Profile These operations can be used t o identify work that is not included in the time guide or described in the methods in t he Service Manual. When these operations are used, a description of the work that has been per formed must be provided. Other work related to engine Op. no. 070-210 This operation can be used when work has been done related to the engine and function group 2 when no applicable meth od descript ion was available. When this operation is used, addit ional in formation is required: Description of work that has been done
Other work related to electrical system Op. no. 070-310 This operat ion can be used wh en work has been done related to the electrical system and function group 3 when no applicable method description was available. When this operation is used, additional information is required: Description of work that has been done
Other work related to transmission, gearbox, travel motor, swing motor Op. no. 070-410 This oper ation can be used when work has been don e related to t he transmission , gear box, travel motor or swing motor and function group 4 when no applicable method descript ion was available. Hhen t his operation is u sed, additional information is required: Description of work that has been done
Other work related to drive axle Op. no. 070-470 This operation can be used when work has been don e related to the drive axle and function group 46 when no applicable method description was available. When this operation is used, additional information is required: Description of requir ed work that have been done
Other work related to brake system Op. no. 070-510 This oper ation can be used when work has been don e related to t he brake system and function group 5 when no applicable method description was available. When this operation is used, additional information is required: Description of work that has been done
Other work related to steering system Op. no. 070-610 This operation can be used when work has been done related to the steerin g system and function group 6 wh en no applicable method description was available. When this operation is used, additional information is required: Description of work that has been done
Other work related to frame link, axle suspension Op. no. 070-710 This operat ion can be used wh en work has been done related to the frame link, ax le suspension and other parts related to function group 7 when no applicable method description was available. When this operation is used, additional information is required: Description of work that has been done
Other work related to cab, air conditioning Op. no. 070-810 This operation can be used when work has been done related to th e cab, air conditioning and other par ts related to funct ion group 8 when no applicable method description was available. Wh en this operation is used, additional information is required: Description of work that has been done
Other work related to hydraulic system Op. no. 070-910 This operat ion can be used wh en work has been done related to the hydraulic system and other parts related to function group 9 when no applicable method descr iption was available. When this operation is used, additional information is required: Description of work that has been done
Service Information Document Title: Parking brake, basic check
Function Group: 090
Information Type: Service Information
Date: 3/26/2020
Profile: A40F Volvo SN 11001-99999
Parking brake, basic check Showing Selected Profile Valid for serial numbers Model
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A40F Volvo SN 11001-99999
WARNING Certain tests are performed with the parking brake released. Make sure that the machine does not start to roll when the parking brake is released. Basic check, purpose The purpose of the basic check is to give quick and reliable information about the system general health. Checking
Explanation
Warning
Not applied parking brake
Leakage
Listen for air leaks
Parameters
Check settings for relevant parameters.
Reference
See Software parameters, description
The normal procedure is that after collecting basic information, reading faultcodes and parameter control perform the basic check (if the fault hasn't been previously determined). Op nbr 090-006 Tools: 88830046 Dump body support
Basic check 1. Start the engine. Release the parking brake twice. Check that the alarm for disengaged parking brake is not activated.
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