Service Information Document Title: Function Group: Appointment and 050 distribution of responsibility
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
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A40D Volvo
WARNING No changes may be made to the electrical system without prior approval from Volvo. Changes may affect machine functions and can result in risks for personal injury or machine damage. Volvo Articulated Haulers AB gives only recommendations for retrofitting based on the characteristics and properties of Volvo chassis and that Volvo Articulated Haulers AB can determine prior to retrofitting without knowledge of the specific case involving retrofitting. Therefore, the responsibility for the retrofit and its compliance to issued requirements rests with those performing the retrofitting. This also applies to the responsibility for the entire vehicle’s characteristics and properties to the extent that they are affected by the retrofit. This includes requirements from authorities as well as general suitability and safety requirements. The dealer/retrofitter is responsible to the customer with regards to giving sufficient instructions about functions and care of the retrofitted equipment and modification of chassis. When a complete vehicle is sold, the dealer is responsible to the customer that the retrofitted equipment has been installed according to the requirements and retrofitting instructions from Volvo Articulated Haulers AB. In case of eventual retrofitting work that cannot contain already known requirements or there are any other doubts, contact Volvo Articulated Haulers AB, Special Vehicles department. The stability may be affected following any and all changes to the basic product. For example, this applies when load body sides are heightened. When special equipment is retrofitted, the instructions in the specification section must be followed. This is especially important in order to maintain the center of gravity within the specified range, both vertically and horizontally. All welding should be performed according to ISO 5817, welding class C. NOTE! No modification of the machine’s hydraulic system is allowed without consent from Volvo Articulated Haulers AB, Special Vehicles department.
Service Information Document Title: Basic check, transmission
Function Group: 090
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
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A40D Volvo Purpose of the basic check The purpose of the basic check is to provide fast and accurate information about the general condition of the transmission. The normal work procedure is to perform the basic check following collection of basic data, reading out error codes and checking parameters, if it has not been possible to determine the cause of the malfunction up to that point. The basic check's tests should be run and evaluated according to instructions in Tech Tool. Tests included in the basic check The first step in the basic check is to operate the machine, to test-run the vehicle. The basic check is then divided into the following tests, which should be performed in the order that they are listed, after reading out error codes, checking parameters and operating (test-running)the machine. Tests: 1. 2. 3. 4.
Op no. 40012-3, Position sensor, gearshift selector, testing The test is used to check that the selected gear position is correctly read in the control unit. Op no. 40025-3, Solenoid valves, testing The purpose of the test is to check that all solenoid valves work. Op no 40098-3, Gears, checking oil pressure, testing The purpose of the test is to check the pressure to brakes and clutches in the transmission. Op no 40027-3, PWM-valves, main and brake pressure, testing The purpose of the test is to check the function of the PWM valves.
Service Information Document Title: Basic checks
Function Group: 090
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
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A40D Volvo NOTE! Basic data must always be collected and error codes and parameters must always be checked before the basic check is started; see Troubleshooting, general. Basic check is performed on each main system. The purpose of the basic check is that it shall give quick and certain information about the status in the sub-system included in each main system. Each basic check is divided into a number of checks to be performed in order. If the basic check does not help to locate the cause of the malfunction, the information obtained helps as guidance for continued troubleshooting together with other service information. The basic check(s) to be performed is determined by the information obtained when the basic data was collected; see Collection of basic data. Basic checks: Engine, basic check Electrical system, basic check Power transmission, basic check Brake system, basic check Parking brake, basic check Steering and hydraulics, basic check
Service Information Document Title: Collection of basic data
Function Group: 090
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Collection of basic data Showing Selected Profile Valid for serial numbers Model
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A40D Volvo The first step in all troubleshooting work is collection of basic data to quickly get a good picture of how the problem manifests itself.
Figure 1 In addition to information about machine and customer, it is important to get as much information as possible about events in connection with the occurrence of the malfunction. The operator can often provide valuable information on the prevailing circumstances when the malfunction occurred since the operator is almost always the first to detect a problem. Often, the malfunction or perceived problems are difficult to recreate if the circumstances are not exactly the same. In these instances in particular, the information from the operator is vital to being able to make correct assessments when continuing troubleshooting. Use the questions below to interview the operator. Note the responses to the questions and save them together with the work order. General data Customer information Dealer information The operator Machine specifications: Machine
Serial number Part number of software in control units
Figure 2 Figure part number software, information display unit Machine hours Engine type Engine number Delivery date Transmission type Transmission number Problem description Have any error codes been generated? Describe the malfunction. When did the malfunction occur? How was the malfunction detected and what happened just before it was noticed? Does the malfunction reappear? How often does the malfunction occur? How long does the malfunction last when it occurs? Does the malfunction always occur during the same conditions, if so, what are they? Does the operator have an idea of what may be the probable cause of the malfunction? Does the problem still exist? Engine data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? Is the engine difficult to start? Is there abnormal smoke development? Are there abnormal engine sounds? Have changes in fuel consumption, oil consumption or power been confirmed? What type of fuel is used? Are additives used in the fuel? If yes, which ones? What repairs or other work has been performed on the engine? Other information? Power transmission, data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? Is there a difference in rolling circumference between the tires that is greater than 1.5%? Other information? Brake system, data Under what operating conditions does the malfunction occur?
External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? When was the last oil filter change? Is there abnormal heat generation from one or several wheels? Other information? Steering and hydraulics, data Under what operating conditions does the malfunction occur? External conditions that affect the malfunction? What type of oil is used? Are additives used in the oil? If yes, which ones? When was the last oil change? When was the last oil filter change? Other information?
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Service Information Document Title: Function Group: Coolant with freezing and 030 corrosion protection
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Coolant with freezing and corrosion protection Showing Selected Profile Valid for serial numbers Model
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A40D Volvo Anti-freeze Check the anti-freeze every 500 hours. At delivery, the cooling system is filled with a mixture of 50% water and 50% Volvo Construction Equipment concentrated coolant with freezing protection down to -25°C. If there's a risk that the ambient temperature drops below this temperature, the freezing protection should be adjusted, see below. Corrosion protection Volvo Construction Equipment concentrated coolant contains active corrosion protection additives to protect engine and radiator. These additives have a limited service life. Therefore, change the coolant every 3000 hours. NOTE! Volvo Construction Equipment concentrated coolant may not be mixed with other brands of coolant or additives. Mixing could have negative effects. Volume and change volume cooling system; see Engine, capacities. The content of concentrated coolant with anti-freeze protection may not be below 40%. 40% provides protection against freezing down to -25° C. 50% provides protection against freezing down to -37° C.
Service Information Document Title: Dealers/retrofitter´s responsibility
Function Group: 050
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
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A40D Volvo It is important that both Volvo Articulated Haulers’ retrofitting instructions and national legal legislation is followed when retrofitting and modifying Volvo chassis.
Service Information Document Title: Hydraulics
Function Group: 000
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
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A40D Volvo HYDRAULICS The following information is displayed on the unit: Engine dep. xxx bar
Shows hydraulic oil pressure from engine-dependent pumps in bar/psi.
Ground dep. xxx bar
Shows hydraulic oil pressure from ground-dependent pump in bar/psi.
Figure 1 HYDRAULICS, all languages VOLVO CONTRONIC - - - HYDRAULICS - - Engine dep.
xxx
bar
Ground dep.
xxx
bar
HYDRAUL TANK VALVE NOTE! The valve is discontinued on machines of later version, see SE9101, Wiring diagram A24. See also 35F9901 Parameters, MO21 module start–stop. The following information is displayed on the unit:
Closed no start Activated Deactivated The key is used to shift between activated and not activated.
Figure 2 HYDRAUL TANK VALVE VOLVO CONTRONIC HYDRAUL TANK VALVE Closed not start Enabled
*
Service Information Document Title: Information and decals
Function Group: warning 000
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Information and warning decals Showing Selected Profile Valid for serial numbers Model
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A40D Volvo Below are the warning and information texts found on the machine. The operator must be familiar with and observe the warnings and information given on labels and plates. Decals / plates that are missing, damaged, painted over or otherwise no longer legible must be replaced immediately. Spare part number (order number) is shown on each plate / decal, as well as in the spare parts catalogue. NOTE! The text “WARNING” is shown on the warning decals in North America.
Figure 1
1. Attaching point for lashing
2. Battery disconnect switch
3. Avoid spraying water at air inlets.
4. Retarder decal
6. Air conditioning filled with R134a. Opening pressure safety 5. WARNING! Do not operate downhill with the gear selector valve (optional equipment) in N-position. Only shift gears with the gas pedal let up.
7. WARNING! Do not use the overhung tailgate (optional equipment) if there is any risk that it can block the load when 8. Emergency exit dumping. Accidents as a result of the machine turning over or the ground giving way can cause personal injuries and machine damage.
9. WARNING! Risk of crushing – frame steering
Figure 2
10. WARNING! Do not enter the work area of a reversing machine
11. WARNING! Rotating fan
12. WARNING! Do not lean in under a raised load body without first securing it.
13. Pressurized brake system
15. Hydraulic oil
14. Tire pressure
16. Fuel
17. WARNING! Only use genuine Volvo coolant VCS – read the Operator's Manual
18. Service decal
Service Information Document Title: Lifting machine, A35D
Function Group: 050
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Lifting machine, A35D Showing Selected Profile Valid for serial numbers Model
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A40D Volvo Op nbr 09001-1
WARNING Never stand under the machine when it is suspended in the air.
WARNING The lifting tool may only be installed with the special nuts supplied with the tool. The lifting tool is considered to be equipment NOTE! The lifting tool must only be installed on the machine when lifting and transporting it. NOTE! It is important that correct tools and special nuts are used and that the lifting tool is installed in the correct way. There are different lifting tools depending on which tyres and rims the machine is equipped with.
Figure 1
A. B.
Clearance between lifting tool and rim, max. 2 mm (0.08 in) Stamped-in part number
There is a stamped-in part number on the lifting tool and it is marked with two decals. They indicate which tool is to be used
with which combination of rim and tyre and which nuts are to be used. Tightening torque for lifting tool nuts, 200 Nm (148 lbf ft)
Equipment No. 91172
Figure 2
Decals on lifting tool 11193585 Lifting tool
Nut
Part. No. 11193585
Part. No. 949495
Used together with: Rim
Tyres
Part. No. 4781741, 22,0–25/3,0
26.5 R25
Equipment No. 81041
Figure 3
Decals on lifting tool 11193586 Lifting tool
Washer + Nut
Part. No. 11193586
Washer part No. 11121276 Nut part No. 11121277
Used together with: Rim
Tyres
Part. No. 11116884 24,0–29/3,0
755/65 R29 800/65 R29
1. Lock the steering joint with the steering joint lock.
Figure 4 Steering joint lock 2. Block the rear wheels. 3. Release the parking brake and disengage the differential locks. 4. Lift the machine using the front eyelets on the frame.
Figure 5
5. Turn the front wheels so that the lifting eyelets on the wheels are positioned as shown in the adjacent figure - in line with the lifting sling.
Figure 6
WARNING Do not lift the machine by the load body eyes. 6. Block the front wheels. 7. Place a lifting sling or strap under the rear end (scow end) of the load body.
Figure 7
8. Turn the front bogie wheels so that the lifting eyelets on the wheels are positioned as shown in the adjacent figure – in line with the lifting sling.
Figure 8
9. Lower the machine. 10. Apply the parking brake.
WARNING The distance between the lifting hook and the wheels' lifting eyes must be at least 8.5 metres. The four lifting slings should be of the same length 11. Lift the machine by the lifting eyes on the wheels.
Figure 9
12. Lower the machine. 13. Disconnect the steering joint lock before the machine is operated.
Service Information Document Title: Lifting machine, A40D
Function Group: 050
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Lifting machine, A40D Showing Selected Profile Valid for serial numbers Model
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A40D Volvo Op nbr 09001-1
WARNING Never stand under the machine when it is suspended in the air.
WARNING The lifting tool may only be installed with the special nuts supplied with the tool. The lifting tool is considered to be equipment NOTE! The lifting tool must only be installed on the machine when lifting and transporting it. NOTE! It is important that correct tools and special nuts are used and that the lifting tool is installed in the correct way. There are different lifting tools depending on which tyres and rims the machine is equipped with.
Figure 1
A. B.
Clearance between lifting tool and rim, max. 2 mm (0.08 in) Stamped-in part number
There is a stamped-in part number on the lifting tool and it is marked with two decals. They indicate which tool is to be used
with which combination of rim and tyre and which nuts are to be used. Tightening torque for lifting tool nuts, 200 Nm (148 lbf ft)
Equipment No. 93015
Figure 2
Decals on lifting tool 11193587 Lifting tool
Nut
Part. No. 11193587
Part. No. 949495
Used together with: Rim
Tyres
Part. No. 11056765, 25,0–25/3,5
29.5 R25
Equipment No. 93302
Figure 3
Decals on lifting tool 11193588 Lifting tool
Nut
Part. No. 11193588
Nut part No. 949495
Used together with: Rim
Tyres
Part. No. 11059979
875/65 R29
27,0–29/3,0 1. Lock the steering joint with the steering joint lock.
Figure 4 Steering joint lock 2. Block the rear wheels. 3. Release the parking brake and disengage the differential locks. 4. Lift the machine using the front eyelets on the frame.
Figure 5
5. Turn the front wheels so that the lifting eyelets on the wheels are positioned as shown in the adjacent figure - in line with the lifting sling.
Figure 6
WARNING Do not lift the machine by the load body eyes. 6. Block the front wheels. 7. Place a lifting sling or strap under the rear end (chute) of the load body.
Figure 7
8. Turn the front bogie wheels so that the lifting eyelets on the wheels are positioned as shown in the adjacent figure – in line with the lifting sling.
Figure 8
9. Lower the machine. 10. Apply the parking brake.
WARNING The distance between the lifting hook and the wheels' lifting eyes must be at least 8.5 metres. The four lifting slings should be of the same length. 11. Lift the machine by the lifting eyes on the wheels.
Figure 9
12. Lower the machine. 13. Disconnect the steering joint lock before the machine is operated.
Service Information Document Title: Recovering and towing
Function Group: 050
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Recovering and towing Showing Selected Profile Valid for serial numbers Model
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A40D Volvo
WARNING Before starting any recovery or towing work, make sure that the parking brake is applied and the wheels are blocked to prevent the machine from rolling. Extreme caution must be observed in connection with towing to prevent accidents and personal injuries.
WARNING If the engine cannot be started, the brake and steering functions will be severely limited. In such cases, towing should only be performed in an emergency situation by experienced and trained personnel and only for the shortest possible distance (see towing). If possible, transport the machine on a trailer. General If possible, the engine should be running while recovering/towing the machine to ensure satisfactory braking and steering performance. Recovering Use a towbar, heavy-gauge cable or chain connected to the towing eyes at the front or rear of the machine to tow the machine to a suitable place or passable road. Towing If the machine has to be towed to a workshop after recovery, use a towbar or heavy-gauge towing cable connected to the front towing eyes. A towbar must always be used if the machine that is to be towed has no brake function. The towing vehicle or machine must always be at least as heavy as the towed machine and have sufficient engine and braking power to tow and brake both machines on uphill and downhill grades. Always tow the shortest possible distance. Maximum towing speed under all conditions is 10 km/h. NOTE! The engine cannot be started by towing the vehicle. Case 1 (with engine running) The gearshift selector should be in neutral and the parking brake in the operating position. The machine can be towed for 10 km without taking special action.
Case 2 (without engine running) Since the transmission is not lubricated when the engine is not running, the propeller shaft between the transmission and dropbox shall be removed. Then lubrication to the dropbox is maintained at the same time as the machine can be steered. Removing the propeller shaft 1. 2. 3.
Place the machine in service position. Block the wheels so that the machine cannot start to roll and release all brakes. Make sure that the front or rear wheels are slightly raised off the ground before removing the propeller shaft's bolts.
Filling compressed air system If necessary, the compressed air system can be filled through the filler valve on the front part of the load unit frame by using compressed air from another machine. Releasing the parking brake When filling through the filler valve on the compressed air tank, the parking brake is released. The required minimum pressure is approx. 470 kPa (4.7 bar). The parking brake control must be in the operating position, that is, not applied. After recovering/towing The following safety measures should be taken before removing the towbar, heavy-gauge cable or chain after recovering/ towing: 1.
Park the machine on a level surface.
2.
Apply the parking brake.
3.
Block the wheels to prevent the machine from rolling.
Service Information Document Title: Steering description
Function Group: cylinder, 000
Information Type: Service Information
Date: 17-Feb-21
Profile: A40D Volvo
Steering cylinder, description Showing Selected Profile Valid for serial numbers Model
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A40D Volvo There are two steering cylinder versions depending on serial number Version 1
Place of manufacture, serial number
Machine EU
Brazil
A35D
–11762
–71113
A40D
–10848
–XXXXX
Version 2
Place of manufacture, serial number
Machine EU
Brazil
A35D
11763–
71114–
A40D
10849–
XXXXX–
Version 1
Figure 1 Version 1 Pos.
Description
Pos.
Description
1
Cylinder barrel
10
Piston rod guide
2
Piston rod
11
Guide ring
3
Roller bearing
12
O–ring
4
Circlip
13
Back-up ring
5
Sleeve
14
Piston rod seal
6
Sealing ring
15
Scraper
7
Piston
16
Spring washer
8
Pin
17
Screw
9
Piston seal
18
Nipple
Figure 2 Version 1 Pos.
Pos.
1
Cylinder barrel
8
Guide ring
2
Piston rod
9
Back-up ring
3
Scraper
10
Piston seal
4
Piston rod seal
11
Back-up ring
5
Back-up ring
12
Guide ring
6
O–ring
13
Piston
7
Guide ring
14
Spiral spring pin
Version 2
Figure 3 Version 2 Pos.
Pos.
1
Cylinder barrel
10
Piston seal
2
Piston rod
11
Guide ring
3
Scraper
12
Piston
4
O–ring
13
Lock pin
5
Back-up ring
14
Circlip
6
O–ring
15
Roller bearing
7
Piston rod seal
16
Muff
8
Guide ring
17
Sealing ring
9
Piston rod seal
18
Nipple
Figure 4 Version 2 Pos.
Pos.
1
Cylinder barrel
8
Back-up ring
2
Piston rod
9
O–ring
3
Scraper
10
Piston seal
4
O–ring
11
Guide ring
5
Piston rod seal
12
Piston
6
Guide ring
13
Spiral spring pin
7
Piston rod seal
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