Preface “This 1st edition of sorvce manual A40D, section 0 and 3 contains specications, instruction for repairing, check Jog and acting as wal ae drawings and agar. Tis Jodtion applies unt is replaced by a new editon. Other sections are organized as follows: "Section S, 0,1 and 2" and "Section 0 and 4~9 For repair instructions concerring the engin, transmis- Sion, Gropbox, drive axes and al conditioning, see the fl lowing service manuals: “Engine D126" “Transmission PT1860"- “Dropbox FL862" “Drive axles AHW71" “Air conditioning R134a" For handling and using the sofware in “PC service too! VOADS Prot, see “introduction manual VGADS Pro’. The too's help menu includes a User's manual J Reter othe curentpubications catalog and SSI (Senice Support Information) forthe reference numberof each respective manual poration numbers refer tothe publication "Time Guide" “The work instructions are based on the use of special toole, E-tools and generally available standard tools. Dra ‘wings for E-ools can be found in this marvin section 0 (03) Miscellaneous. Al iting devices must comply with furtent existing requirements, national standards and regulations for liting devices. The Volvo CE Group will Veccept no responsibly if other iting devices, tools ‘or work methods are used other than those descri- bod in this service manual. AAlnformation and data inthis service maral ae curent and val atthe time of publication Volvo Coristruction Equipment reserves the right to modiy specifications and equipment without prior notice a WARNING! Warning symbol! ‘This symbol appears at various points throughout this ser- Dyce manal in conuncson wn waring statements, The ‘appearance of the symbol means "Warning, stay alert! ‘Your safety is involved!” EU: from and incl. serial no. 10001 USA: from and incl. serial no. 60001 Brazil: from and incl. serial no. 70001 Korea: from and incl. serial no. 80004 General Electrical and Information Systems Ref nr 21 1 491 3079,gSection 0 General General General Description .. 0:2 Specifications General Product identification plates Dimensions .... Dimensions, with tires 29.5 R-25 Capacities . Oil and fluid change, intervals Filter change, intervals... Weights Tightening torques : Standard tightening torques Engine, general specifications .. Fuel system Lubrication system Cooling system .. orto 0:11 ont4 O15 0:16 0:16 0:16 Thermostat, specification .. O17 Radiator (cooling) fan pump, specification .. O:17 Radiator (cooling) fan motor, specification o:i7 Air cleaner, preheating of induction air, specification ...... 0:17 Intercooler, specification .. pee 0-10) Electrical system .... 0:18 Power transmission .. 0:20 Transmission, specifications 0:20 Oil pressure, transmission .. 0:21 0:24 0:24 0:25 0:27 0:28 0:31 Brake and compressed air system Control system ... Hydraulic system .. Tire equipment and recommended tire pressures Retrofitting Dealer's/retrofitter's responsibility ‘Appointment and distribution of responsibility 0:31 0:31 Transport instructions General Recovering and towing ... 0:33 Lifting of machine 0:35 Tools E-tools Drawings of E-tools 0:37 ostFig. 1 Articulated hauler A400 0:2 Articulated hauler A40D consists of two main sections, the trac- tor unit and the load unit. The two units are joined by the frame joint, which allows movement about a vertical bearing for steer- ing. The frame joint also allows twisting of the units in relation to each other along a horizontal axis, ‘The tractor unit consists of a six-cylinder diesel engine, trans- mission and dropbox as welll as a drive axle, The cab is rubber- mounted to the frame. The frame is independently suspended in relation to the drive axle, ‘The load unit consists of a frame, elevation load body, as well as a front and rear drive axle, which are linked by the bogie suspen- sion. ‘The articulated hauler has constant 4-wheel drive with the possi- bility of engaging and disengaging 6-wheel drive. It has a longi- tudinal differential lock in the dropbox and differential locks in the drive axles.Fig, 2 Type and product numbers, articulated hauler A40D D120 - 8188166 PT 1860 - 22517 AHW 71 L- 23789 FL 862 - 22529 ‘ABW 71 M- 23780 AHW 71 N- 23791 0:3Specifications General Product identification plates The following text with numbers refer to the figure showing the product identification plates that should be fitted on the machine. ‘The model designation and Product Identification Numbers (PIN) must always be correctly quoted when ordering spare parts, making telephone inquiries or in any correspondence regarding service matters. Fig. 3 Position of product identification plates 0:4 = 5 arsozo00 1 Product plate with Product Identification Number, PIN , for the complete machine (includes model, product and serial ‘numbers, machine weight, engine power, and CE approval, Where applicable). The plate is located on the left side of the tractor unit frame by the steering joint. 1A : Product plate, version for markets outside the USA. 1B : Product plate, version for the USA market. 2 The machine's serial number is also stamped into the right side of the tractor unit frame, by the steering joint.ae Drive axle serial numbers are located on the axle housing. Dropbox serial number is located on the rear right side of the dropbox. Brake type designation and serial number is located on the brake housing end, ‘Transmission type designation and serial numbers located on the left side of the transmission. The decal “Important Engine Information’ is located on the front end of the engine and on the left side of the tractor unit frame by the steering joint (complementary plate). Engine type designation, part and serial number is stam- ped into the left side of the engine block. Cab type, type approval and serial number is located on the left inside the cab. 05Dimensions ‘The letters in the figure refer to the text on the next page. 06Dimensions, with tires 29.5 R-25 Dimensions apply to unloaded machine __| sion” | mm | Inches Total length = A rat | 445.27 Total length, tractor unit ~ jAt 5469, | Total tength, oad unt ae [eee | 25007 Load body length, standard body 8 [s700 | z2559 ‘Total height, at top of exhaust pipe c 3746 147.48 Height to cab roof _ ci «| 3626 142.76 Wath across cab roof ce [1768 [eat ‘Overhang, towing eyes [100 [12205 [Distance front axe center aiuaton pin [E [1276 | 028 Distance, drive axles 7 F 4451 175.24 [ Distance, bogie axles @|1840 [7638 ‘Gverhang, rear [tees r.77 Overhang, frame : ee Toacing height T9075 [188.08 Height to load body K 2492 att | Free dumping height ee “oll height, elevated Toad body M7984 | 29078 Outertumingradius nN esea [tao Toner turing radius Nt [408665 [[Ouisice wiath, load body oO _ [see [12866 Trside width, load body [sore [rete [ Minimum ground clearance, load unit a [es [e575 Minimum ground clearance ale, oad unt ai |rt_|e087 | Maximum height, upper body plate u 3590 141.34 “Track width, load uni Vv [2886 | 10078 “Total with, foad uni waa [195.12 Minimum ground clearance, actor uni x fe? [aaa Minimum ground clearance axle, wactorunt [xi [639 [25:18 Minimum ground clearance, itch xe [705 [a0.18 “Track width, tractor unit Y_ [60810878 “otal with tractor unt Z_ [esse [195.42 “Angle of approach ates" Dumping angle 2/70" Maximum steering angle (as? o70:8 Capacities when changing| total] [Eanes Titore (12.04 US gal] Soto [FOZOUS ga Cooling sim “bo hore 3:76 US gail 17 er (0.89 US ea Taatieorisieny eee 7 Wore (12.47 US gal] #85 ors (128 US ga Dropbox ~ 7 liters (1.85 US gal) "10.5 ters (2.77 US gai)| Front axle (drive axle) 55 liters (14.52 US gal)| 55 liters (14.52 US gal) Front Bogle ao 56 ters (14.78 US gall 56 Were (1470 US ga Rear bogie axie ~ 55 liters (14.52 US gal)] 55 liters (14.52 US gal)/ Hub reduction Titers (1185 US gal) 7 iters (1.85 US gal) Frame joint bearings 4 iters (7.06 US gal 4 ters (1.06 US ga} Brake cooling olf tank 98 iters (25.87 US gal)| 103 liters 27.19 US gan] Brake cooling system 140 liters (86.96 US gal) Brakeltiydraulic system 145 iters (88.28 US gal] 400 liters (105.6 US gal] » Hydraulic oll tank 250 liters (66 US gal) Fuel tank 480 liters (126.72 US ga)| ' Check and adjust the oll level after the oll change according to the Operator's Manual. Oil and fluid change, intervals [Hour Engine) 500 —| Transmission ~_ [1000 Coolant 2000 Frame joint 2000 Brake cooling oll 1000 Dropbox 72000 Drive axles: 2000 Brake ollHyadraulic ol! 72000 ‘2, Conditions for the interval to apply, see Operator's Manual, Engine, changing oil, Filter change, intervals Engine Hour Oil fiters 500 Fuel fiter 4000 Water trap filter 1000 Air cleaner, main fiter (primary) _| 1000 ‘Air cleaner, inner fiter 2000 (secondary) (Coolant fiter 1000 Suction strainer, cleaning, power | 1000 take-offTransmission - [Hour Main oil fiter 1000 Lube oil fiter 7000, Breather fiter 1000 Suction strainer, cleaning 72000 Dropbox [Hour | Breather fiter [2000 Suction strainer, cleaning 2000 Brake system Hour Pressure ol fiter 72000 Breather fiter, rake cooling oil | 1000 tank Drive axles: Hour Breather fiter 1000 Cab [Hour [Primary titer 1000 Main fiter 72000, Hydraulic system Hour Breather fiter hydraulic oiltank | 1000 Retum oll fiters 2000 Retum olf fter, cooling fan 2000, 0:90:10 Weights kg Ibs 7 (approx) ‘Operating weight 31300 [69017 Front axle tes00 | 35942 Bogie axies 14970 | 33009 ‘Total (inl. operator and fullfuel tank) | 31270 | 68950 Max. load allowed on front axie 19170 | 42270 | Max. load allowed on bogie axles 49100. | 108266 Load capacity ‘37000 | 81585 “Total weight, maximum 68270__| 150595 Engine hood with front member 250 551 Engine and transmission, complete 1890 4035) Engine, complete 1360 2999 Transmission 470 1036 Dropbox 535 1180Fig. 5 Tightening sequence, valve cover Nm _ Stop1 20 Stop2 20 Step 3 Step 4 Tightening torques NOTE! For bolts and nuts without specified values, see page 0:19. Engine | [Also refer to Service Manual “Engine D12C* _ Nm [kpm]ibfft | | Engine - fiywheal housing (18 bolts) | 192 |19.2|97.96 | Flywheel ~__[207 [20.7 | 152.68 Flywheel housing - transmission 9 [9d [67.12 [Flex plate - torque converter or [oa lerte Rear engine mount - engine [75 [785 | 136.46 | Fear engine mount, rubber cushion— | 185 | 18.5 | 136.46 frame Rear engine mount— rubber cushion _| 185 | 18.5 | 136.46 Front engine mount, rubber cushion- [70 |7.0 [81.63 frame Front engine mount rubber cushion | 115 | 11.5 [84.62 Control vaive (VEB) [20 [20 [14.75 Hydraulic pumps oi [et [ezi2 Valve adjusting screw, lock nut 38 [88 [2808 Valve cover, see Fig. 5 Unitinjectors, see Fig. 6 kpm oe ft Angle torquing 20 14.26 2.0 14.26 ors e0=5Fig. 6 Tighten the adjusting screw to zero clearance ‘against the camshatt, then turn 8-4 hex bolt edges 0:12 [Type Pre-load (setting with gauge) Bosch [689201 mm (2.71 0.004 in) Type Lucas Pre-load ‘3~ 4 hex bolt edges (0.75 +0.1 mm) (0.03 + 0.004 in) see Fig. 6) Torque, lock nut for adjusting screw ‘52 Nm (88.36 Ibf.ft) Transmission Also refer to Service Manual “Transmission PT 1860" Dropbox Also refer to Service Manual "Dropbox FL862" [Propeller shafts i Nm [kpm | ibtft Flange bolts, propelier shafts 165/185 | 196.46 Wheels aa Nm [kpm | Ibfft Wheel nus ‘00/800 | 590.08 Brake and compressed air system Nm [kpm [ior ft Parking brake caliper plate-frame [402 | 40.2 | 206.52Fig.7 Hitch (steering and frame joint) @Voanon+ " 12 13, 14 Nm 2412 740 #120 e212 740 #120 8212 82212 91413 544 £78 91413 544 278 91313 1000-1500 e212 e212 kpm. 8221.2 74.0 412.0 82212 74.0 412.0 54.4 27.8 3 84.4 37.8 1313 100-150 Ibfft 60.48 + 8.85 545.82 4 88.51 60.48 + 8.85 545.82 + 88.51 60.48 + 8.85 60.48 + 8.85 67.122 9.59 401.25 + 87.53 67.124 9.59 401.24 57.53, 67.124 9.59 737.6-1108.4 60.48 + 8.85 60.48 + 8.85o:t4 Standard tightening torques. NOTE! Torque values should be increased by 10% for flange bolts type USFS. Bolts and nuts should be cleaned and lubricated with oil. The tightening torques in the following tables apply to bolts and huts with tensile strength noted below. The tables should be used as a general instruction for tightening bolts and nuts which have no specified values. TENSILE STRENGTH 8.8 Metric coarse and fine threads Thread Nm kpm| oF ft Me 1032] 1.0402 | 74a15| Me 2435] 24205 18435) Mio 4810 48210 3527.4 Miz 85418 a5i8| 63213) Mia 140225) 14.0326 03 218] Mie 220245) 22.0445 160 233 M20 [430 85[ 43.0385) 320263) Maa 740160, 74.0180] 550110) TENSILE STRENGTH 10.9 Metric coarse and fine threads Thread] Nm] kpm] lof ft] Ma 1222) 12 402| oa15 wa 3035 3.0305 22485 i Mio] 60 510) 6.01.0) 4a75 mia 105320[ i0.5s20| __7eatas| ial 175230, 17.5330 130 422 Mie 275445] 27.5245 204 #33 M20) 540290] _54.0209.9] 400 +66] Maal 8054160 805x160] _so4zt18 UNC threads, coarse Thread Nm kpmy br ft] 14" 922 0:9 203| 66a15 sie" 1844 7830.4 13330 Ea EF 3.3408] 24359) 78 Bantd 5424 40 #10] iy 80220 80320 59215 oie" 120280| 12.0430 89 429] 51" 170240] 17.0 4.0) 130 230| Za 300270|_30.027.9] 220 #52 7] 4854118] 4852115] ‘360 285] V[7e5178|__7252175| 8302130Engine, general specifications Aso refer to Service Manual "Engine D120" Engine Make Vows Tyee Directinjected, 4-stroke, turbocharged and intercooled diesel engine with electronically controlled injection Designation Di AAE2 Product number ‘188166 Flywheel output at 30 v/s (1800 rpm) ‘313 KW (426 hp) SAE J1349 Gross Flywheel output at 90 v/s (1800 rpm) 307 KW (417 hp) SAE J1949 Net Flywheel output at 90 /s (1800 rpm) 307 KW (417 hp) DIN 62718 "Torque at 20 We 72100 Nm (214 kpm) SAE J1349 (1200 rpm) Gross Torque at 2008 £2052 Nm (209 kom) SAE J1349 | (1200 rpm) Net forque at 20 0s, 0 fier aee £2052 Nm (209 kom) DIN 6271") Number of eylinders 6 Cylinder Bore 190.17 mm (6.12 in) ‘Stroke 150 mm (6.91 in) Gylinder capacity 12 liters (8.17 US gal) ‘Compression ratio 18.51 Injection order 153624 {dle speed, low 10 40.8 1s (650 +50 rpm) Idle speed, high ‘35 vs (2100 rpm) 2. with cooling fan at base speed, 300 KW (408 hp) is the output with the fan at max. speed, which corresponds to DIN 70020. ». with cooling fan at base speed. 1998 Nm (204 kom) isthe output with ‘the fan at max, speed, which corresponds to DIN 70020. Power take-off (PTO) Connections for hydraulic pumps | 4 Turbocharger Designation GT 4504 44 PS-18d ‘Lubrication Pressure oll from the engine oil fter bracket Valve mechanism Valve deviee “Top valves Valve clearance, warm/cold engine: Inlet valves (0:20 mmm (0.01 in) Exhaust vaives 1,60 ram (0.08 in)0:16 Fuel system Feed pump Tyee Gear pump Designation FHIEM 12 8-226078 Feed pressure ‘350 kPa (60.75 pel) [Unit injectors Type Electronically controled injec- tion volume an injection timing [Number of 6 Lubrication system Oil pressure, minimum at low idle | 150 KPa (21.75 ps) speed (warm engine) Oil pressure, operating speed (warm | 300-550 kPa engine) (43.50-78.75 psiy Cooling system Type “Two separate systems with two different coolers Thermostats, number of 2 ‘Thermostat, primary system: [Type Piston thermostat Begins to open at 2 °0 (179.6 F) Fully open at 92°C (197.6 °F) Rel vate oping pressure (cap, | 50 KPa (0.5 bar) (7.25 ps ‘expansion tank) ‘Thermostat, secondary syste Type Diso thermostat Bogins to open at 35°C (181 °F) Fully open at 70°C (15°F) Pressure 50 KPa (0.5 bar) (7.25 psi)Thermostat, specification [ Thermostat, primary system: Type Piston thermostat Number of i i Begins to open at 22°C (178.6 F) Fully open at 92°C (197.6 °F) Pressure ‘50 KPa (0.5 bar) (7.25 psi) ‘Thermostat, secondary system: Type Disc thermostat Number of 1 Begins to open at 55°C (131 °F) Pressure Fully open at 70°C (158 °F) 50 KPa (0.5 bar) (725 psi) Radiator (cooling) fan pump, specification [Pump 6, 6 Radiator (cooling) fan pump Type Position on machine ‘Axial piston pump, variable displacement ‘Left side of transmission, in series with pump 1,2 Displacement 2B em®r (1.71 inh) Flow volume, max, Radiator (cooling) fan motor, specification 34 Vimin (6.98 US galimin) | Radiator fan motor Number of 2 Type Fixed piston motor Designation ‘TOF MI1/21W-XKGIT6D lpm at max pressure 3000 rem Displacement 11 emf (0.67 in) specification Air cleaner, preheating of induction air, "Type of air cleaner ‘Air cleaner with connections, preheating of air iy titer with inner element Triple-stage air cleaning: 7, Precieaner 2. Main filter Safety fier reheating coll Tn induction pipe 0:17one Intercooler, specification Charge-air cooler (Intercooler) Type Airfar max. 50°C (1221 Correct value (command varia- | 80°C (122 °F) bie) at outside temperature Electrical system above 25 °C (77°F) Correct value (command varia- | Outside temperature + max 25 °O ble) at outside temperature | (77°F) below 25°C (7 °F) Systom voltage 24 V Battery Number of F Ground conecion Minas ( Bator capacity 170K Battery disconnect switch connected on (-) side | Minus (Coir ewiocomnectodon (eide| Mins | Battery electrolyte density 74 Filly charged battery 0.00128 Wye? Battery should be recharged at 0.00425 tye? ‘Alternator Type Alternating curent Zener Designation wt ( Effect (rated output 1540 Voitage, max ov Current, max Ex Beit tension, 698 Operator's Manual Starter motor Designation Delco mT oav] Output 72 KW (0.65 hp)Fuses ~~ | Current rating Number of | Electrical distribution box «| 3A it [Electrical cisvibuton box [5A 7 Electvical distibution box | 10 [9 Electrical distribution box 15A 13 Electrical distribution box 204 Tt Eiectrical distribution box 2A 1 Main fuse, cab (ooatedin engine | 25 8 7 comparment) Delayed sop TOA 7 Preheatng eal, check 5A 7 Main fuse, preheating coil T1008 (located in engine compartment) _ | Bulbs - tractor unit Watt [Base Headlights 7 70 [Ht Parking lights 3 BAB Direction incicators 2 BA Ss Instrument lights a [12 Switches lz BASS Main instruments, coir his [2 ‘Main insrumenis, ihting ie Rotating beacon (optional eqiament) | 70 Hi Bulbs -load unit ~ Tal ighis i (=D Brake igh 7 LED Direction incioators 2 Backup light 70 7 Cold start device “| Type Cai Ouipat Baw 268 hp) Time relay, engagement period integrated | Variable o:19Power transmission Speed ranges (max.) Mact 1e equipped with tires 29.5 R-25 Gear [Low t Forward ist___ | @kinih (.72mph) [9 km/h (6.58 mph) 2nd | @ kwh (6.58 mph) _| 13 krmih (8.06 mph) 3rd___| 78 kmih (0.92 mph) [23kmMm (14.26 mph) ath [28 karvh (14.26 mph) 83 krvsh (20.46 mph) ‘Sth [30 karvh (78.60 mph)| 42 krvh (26.04 mph) | 6th___| 40 kin (24.80 mph)| 85 kavh (84.10 mph) Reverse z [ist 6 km/h (3.72 mph) _| 8 km/h (4.96 mph) ( 2nd | 10 kami (6.20 mph) | ¥4 kmh (8.68 mph) Transmission, specifications Transmission 4 Aso fro Senice Manual "Transison PTT Belgraton PTTeE0 Type Fully automatic planetary transmission Product number 22517 Reduction rati Gear Re [Rt Fi F2 Fa Fa F5 Fe Reduction ratio, converter: Retarder Type PFE Max. braking torque 1300 Nm (058.88 (bff) 0:20Oil pressure, transmission Pressure checks Check pressure at 1200 rpmv/70 °C (158 °F) oil temperature. Pressure is given in MPa (psi). Pressure checks, automatic position, connected ECU N D R Converter Lock-up Pi 0.561008 | 1,720.15 | 172018 | 1,8020.16 (ei.z=11.6) | (246.5821.75) | (246.5421.75) | (274.05221.75) PCT 0.56008 | 0.561008 | 0.561008 | 0.5620.08 (1.2116) | (@t2ette) | (et.2et1.6) | (81.2411.6) PS 0.230.07 ~0,2310.07 0.23+0.07 0.2340.07 (33.35210.18) | (99.35210.15) | (93.35#10.18) | (83.95#10.15) iki 0 0 Toi | (0 (246.5121.75) | K2 0.5620.08 | 0 1.240.12 1.8920.15 (61.2511.6) (1748174) | (274.05421.75) Bt 0.4740,08 ° 1420.12 ° (68.15211.6) (203+17.4) B2 | oO oO 1,340.12 0 | (188.5417.4) BS ° ° 1720.16 0 (246.5+23.2) Ba o2i02 0 1720.16 | 1.8080.15 (29.0429.0) (246.5+23.2) | (274,0521.75) [85 0280.2 T7016 | _7.8980.15 | (29.0429.0) (246.5423.2) | (274.05421.75) Lock-up ° ° 1,980.4 1120.1 (275.5414.5) (159.5214.5) ‘The gearshift selector is used to select gear. Gear engagement is controlled by the control unit after impulses from sensors. Clutches and brakes are activated by solenoids via relay valves in the transmission control system ‘When selecting a specific gear, a combination of brakes and clutches are engaged. ‘When shifting gears, a clutch/brake is engaged at the same time as the brake for the previous gear is disengaged. oatPressure check connections, position Fig. 8 Transmission, left side 1 Connector EH P1 Main pressure (R1/4") \ B3 B2B1 K2 oro Fig. 9 Transmission, right side PC2 Torque converter pressure OUT (F1/4") PS Lubrication oil pressure (R1/4") K2 Clutch pressure, reverse gear (Ri/4") 'B1-B5 Clutch pressure, brakes (R1/4") Ri Retarder pressure IN (Fi1/4") PR2 — Retarder pressure OUT (RI/4") 0:22Fig. 10 Transmission, seen from underneath Pt Main pressure Ki Clutch pressure, forward gear (R1/4") PC1 Torque converter pressure IN (F1/4") PLU Look-up pressure (direct clutch) (R3/8")Transmission, clutches and brakes Ki K2 Bt Be B3 B4 BS © seavio 8 a SE4213 SE4208 SE4214 SE4203, Fig.tt Clutches and brakes in the transmissi Ki Forward, ist — 6th gear Ke Reverse, 6th gear Bi 4th gear B2 Sth gear 83 ‘rd gear Ba 2nd gear, forward and reverse BS ‘1st gear, forward and reverse A Control system B Pump c ‘Torque converter D Retardor‘Sensors and solenoids in the transmission Z_ MA4201 -MA4208/ | Solenoids, speed gears Si-S5 | MAa206/87 Solenoid, forward gear MAa207/58 ‘Solenoid, reverse gear, 6th gear forward PWMAZ01/S11 | Modulating valve, main pressure PWMa202/813 | Modulating valve, brake pressure PWM4203/S14__| Direct clutch (Lock-up) _ SE4202 [ Sensor, transmission oil temperature (oll sump) SE4203 ‘Sensor, transmission oil level (oil sump) SE4212 ‘Sensor, engine speed, input speed (transmission) ‘SEARS ~ [Turbine speed, behind cover for connector EH SEA214 ‘Sensor, lubrication oil pressure 0:250:26 Dropbox Also refer to Service Manual "Dropbox FL862" Make Type Designation Product number Volve Fise2 Mechanical with higiow range 122525 Powor take-off 1 power take-off for ground dependent hydraulic pump Reduction ratio, ow | 1.188:1 Reduction ratio, high | 0.851: Longitudinal Dag-clutoh, 100% lock Bearing clearances 010-020 ( pata Tnomedat sat [70-020 Dire o.f9-028 Fear oupitsrah [010-020 Front output shat | 0100.20 ( Tavera [005-050 Drive axles Aso refer to separate service manual fo cive axles [Front dive aie Roar dre me ] stron [feadunt™ [adam | @ Wate Veve——[vovo Vero Toe AW 7TL [aR TM [aRWTTW Prosudnanber [276i [2790 701 alae Designation 7At [7a1 7A Reducion aio [aos [as 1 Hab reduction t Reduction ratio 4.833) 4.833 [4839 Differential lock Mechanical dog-clutchBrake and compressed air system Brake system Brake oil pump ‘Type Variable piston pump, tandem Designation ‘AioVS018DR 3-1R-XSC12N00-S0981 (Right front) Displacement 18 om®r (1.1 int) Pressure, max. 25 MPa (3625 psi) ‘Capacity at 34.2 v/s (2050 pm) _| 43 min (11.95 US gal/min) | Operating pressure, max. 25 MPa (3625 psi) | Replacement is recommended at [8 Umin (2.11 US gallmin) | max, pressure and leak-oil flow [Reduction ratio, engine - pump _| 1.22 [Rotational direction Clockwise ‘Accumulator Type | Diaphragm accumulator Designation D0, 75-250 Capacity 0.751 (0.2 US gal) Number of iat Pre-charge pressure, min 8.5 MPa (1292.5 psi) Pre-charge pressure, max. 10 MPa (1450 psi) ‘System pressure, max.| 25 MPa (3625 psi) Relay valve Type Pilot-controlied relay valve Parking brake Type ‘Compressed air, mechanically oper- ated disc brake, acting on load unit propeller shatt ‘Service brake Type Fully hydraulic, divided into two cir- cuits. One circuit each for the tractor unit and load unit. Foot brake valve Type Two-circuit slide valve with built-in retarder control Max. operating pressure 13.8 MPa (2001 psi) 0:270:28 Brake cylinder for propeller shaft parking brake Type ‘Compressed air oper- ated parking brake Designation DPX 195 ] Release pressure 6.2 bar (69.9 psi) Brake disc, parking brake Thickness 25.6 mm (1.07 in) Thickness, min. 20 mm (0.79 in) Brake pads, parking brake Thickness: 17.5 mm (0.69 in) Thickness, min, ‘5mm (0.2 in) Compressed air system General Compressed air is used for: = exhaust brake high/low range shifts in dropbox = parking brake = differential locks ~ sixewheel drive - hom = seat suspension (optional equipment) ‘Compressor Type Single-cylinder piston ‘compressor Designation 0z5743, Displacement 225 em4/r (13.73 init) [Compressed air regulator | Included in air drier 11059831] ‘Cut-in (engagement) pressure| 670-750 kPa (97.15-108.75 psi) ‘Cutout (unloading) pressure | 790-830 kPa (114.55-120.35 psi) ( ‘Compressed air tanks Regeneration tank 411 (1.06 US gal) Circuit tank 20 (5.28 US gal) Safety valve, opening 930 kPa (134.85 psi) pressure Pressure retaining valve Overflow pressure [650 kPa (94.25 psi)Control system [Type Hydro-mechanical articulated steering Steering wheel tums, lock-to- | 3.4 tums 7 lock ‘Steering angle 2x45 = Time, steering angle = 3.2 sec, | Steering gear Type Rack and pinion gear Control valve, steering | Included in central block 11068549 [Type ‘Slide (spool) valve ‘Steering cylinder Number of 2 ‘Damping cylinder for steering Damping spring, prefoad _| 2.2- 3.8 mm (0.09-0.15 in) 0:280:30 Hydraulic system Hydraulic pump, engine dependent for fan drive, steering and dumping as well as ground dependent for secondary steering. Hydraulic pump, left front, engine dependent Type Designation Displacement [Variable piston pump ‘A1OVO4SDFRIB2R- | XSC12K68-S0973 45. om%Pr (2.75 in®/r) Capacity at 34.2 1/s (2050 rpm) Operating pressure, max. 108 Vimin (0,28 Us gal/min) 25 MPa (3625 psi) _—| sure and leak-oil flow Reduction ratio, engine - pump Replacement is recommended at max. pres-| 15 Umin (3.96 US gal) 4.22 Rotational direction Clockwise Stand-by pressure with disconnected LS 1.6 MPa (232 psi) Hydraulic pump, left front, engine dependent Capacity at $4.2 r/s (2050 rpm) ‘Type Variable piston pump Designation ‘AVOVORBEGEX/SAR- XSC12N00-81153 Displacement 28 om/r (1.71 ine) 67 Vmin (17.69 US gal/min) ‘Operating pressure, max 25 MPa (3625 psi) Replacement is recommended at max. Pressure and leak-oil flow 12 Umin (8.17 US galimin) Reduction ratio, engine - pump 122 Rotational direction Clockwise Hydraulic pump right front, engine dependent Type Variable piston pump Dosignation Displacement ‘A{OVO4SDFRIS2A- xecraksestaze « 45 om*r (2.75 in%r) (Capacity at 34.2 1/s (2050 rpm) 108 Vmin (28.51 US gal/min) Operating pressure, max. 25 MPa (3625 psi) Replacement is recommended at max. pressure and leak-oil flow 12 Wimin (8.17 US galimin) Reduction ratio, engine - pump 1.22 Rotational direction Clockwise Stand-by pressure with disconnected LS | 1.6 MPa (232 psi)Hydraulic pump left rear, engine dependent “Type - ~ Variable piston pump Designation ~___ [ATOVOBODFRIEZL- XWC12K68-80973 Displacement 60 om®/r (8.66 in’) Capacity at 34.2 is (2050 rpm) 143 Vimin (87.75 US gal/min)] ‘Operating pressure, max. 25 MPa (8625 psi) Replacement is recommended at max. pres-| 24 Umin (6.34 US galimin) sure and leak-ol flow Reduction ratio, engine - pump 1.22 Rotational direction Countor-clockwise [ Stand-by pressure with disconnected LS (6 MPa (232 psi) Hydraulic pump left rear, engine dependent Type Variable piston pump Designation ~ ‘Aiovo2sEDEX/S2L- XSC12N00-S1153 Displacement 28 om°/r (1.71 in®/r) Capacity at $4.2 ris (2050 mpm) 67 Vmin (17.69 US galimin) Operating pressure, max. 25 MPa (3625 psi) Replacement is recommended at max. pres-| 12 Vmin (8.17 US galimin) sure and leak-ol flow Reduction ratio, engine - pump 1.22 Rotational di ction Counter-clockwise | Hydraulic pump right rear, engine dependent [Type Variable piston pump [Designation ‘A10VO60DFR/S2L- | XUC11NOO-So882 Displacement [60 em (3.66 in®/) Capacity at 34.2 1s (2050 rpm) 143 Uimin (87.75 US galimin) ‘Operating pressure, max. 25 MPa (9625 psi) Replacement is recommended at max. pres-| 24 I ‘sure and leak-oil flow Fieduction ratio, engine - pump 122 Rotational direction Counter-clockwise Stand-by pressure with disconnected LS [1.6 MPa (232 pai) (6.34 US gal/min) 0:31Hydraulic pump 6, ground depend- ent ‘Type ~ Variable piston pump | Designation A10V071DFR/31R- XSC11NOO-so8e2 Displacement Th emi (4.83 nin) Operating pressure, max 25 MPa (3625 psi Rotational direction Clockwise ‘Stand-by pressure with disconnected | 1.6 MPa (232 psi) LS and Q = 0 l/min (US gal/min) yar Number of 2 - Type Piston motor, fied deplacement ( Designation "ATOF MT7S1W/-XKHT6D Displacement 11 emir (0.67 nS) Max. pressure 25 MPa (250 bar}(3625 psi) | Brake cooling oil pump, axles ( Type Gear pumps [Dumping control (dumpleven —T Dumping control (dump lever) Type Plot valve, 4 positions Designation 71059811 ee 1) 000) Tecladed in cmv back | ¢ Controt valve, dumping 11063549 Type Slide valve, 4 positions Designation 11063549 Rolief valve (0.82 MPa (8.2 bar) (118.9 psi) Pressure reducing valve, dump lever _| 3.8 MPa (38 bar) (651 ps) Pressure limiting valve, dump lever__| 3.8 MPa (88 bar) (651 psi) Pressure limiting valve for B-pot__| 3.8 MPa (88 bar) (651 psi) Non-rotum valve with backpressure [0.2 MPa (2 bar) function (28 ps) Hoist cylinder Type Double-acting Number of 2 Times for dumping and lowering Dumping time 12 06. Lowering time 10 sec. Dumping angie ‘Dumping angle load body 70° o:s2Tire equipment and recommended tire pressures AEE ee AdoD 6°6 ' a ta Sneed saewcunes ‘oa nPa= B80 pl ‘ware 580 pl [Beka 640 pat ‘a0 KPa= 680 pa ‘asras™ oP20 aps Michelin 288 RAS" KADT ‘Kenta nokta VOLVO Sater ) SCRE SN RANRNS SSCrat Fig. 12 ' . Retrofitting Dealer’s/retrofitter’s responsibility Itis important that both Volvo Articulated Haulers’ retrofiting instructions and national legal legislation is followed when retro- fitting and modifying Volvo chassis. y Appointment and distribution of responsibility A WARNING! No changes may be made to the electrical system without prior approval from Volvo CE. Changes may affect machine y functions and can result in risks for personal injury or machine damage. Volvo Articulated Haulers AB gives only recommendations for retrofiting 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 involv- ing retrofiting. ‘Therefore, the responsibility for the retrofit and its compliance to issued requirements rests with those performing the retrofiting, This also applies to the responsibilty 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, 0:330:34 ‘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 retrofiting 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.Transport instructions General Recovering and towing A WARNING! Before any preparations are started for recovering or tow- ing, the parking brake must be applied and the wheels should be blocked to prevent the machine from rolling. Extreme caution must be observed when recovering or towing in order to prevent accidents and personal injuries. A WARNING! If the engine cannot be started, the brake and steering func- tions will be severely limited. In such cases, towing should only be performed in an emergency situation by experi- enced and trained personnel and only for the shortest pos- sible 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. 0:350:36 Towing = Ifthe machine has to be towed to a workshop after reco- very, use a towbar or heavy-gauge towing cable connected to the front towing eyes. = Atowbar must always be used if the machine thats tobe ( 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 gradients. ~ Always tow the shortest possible distance. ~ Maximum towing speed under all conditions is 10 knvh (6.2 mph). NOTE! Itis not possible to start the engine by towing. ¢ Case 1 (with engine running) ‘The goarshift selector should be in neutral and the parking brake in the operating postion. The machine can be towed for 10 km (( (6.2 miles) without taking special action. Case 2 (without engine running) Both output propeller shafts must be disconnected from the ‘dropbox since the transmission and the dropbox do not receive any lubrication when the engine is not running. Filling compressed air system ( lfnecessary, the compressed air system can be filed 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) (68 psi). ‘The parking brake control must be in the operating position, that is, not applied. After recovering/towing q The following safety measures should be taken bofore 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Lifting of machine Op. no. 0901-1 Tools: A WARNING! Never stand under the machine when it is suspended in the air. 1 Lock the steering joint with the steering joint lock. 2 Block the rear wheels. 3 Release the parking brake and disengage the differential locks. 4 Lift the machine by the front lifting eyes in the frame. 0:37Fig. 15 15° + 15° 15° + 15° Fig. 17 0:38 5 Tum the front wheels so that the lifting eyes on the wheels are positioned as shown in the adjacent figure. A 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, 8 Tum the front bogie wheels so that the lifting eyes on the wheels are positioned as shown in the adjacent figure, 9 Lower the machine, 10. Apply the parking brake. A WARNING! The distance between the lifting hook and the lifting eyes on the wheels must be at least 8.5 meters (28 feet). 11 _ Lift the machine by the lifting eyes on the wheels. 12 Lower the machine. 13 Disconnect the steering joint lock before the machine is operated. ( ( qo7 Fig, 19 £1750, Differential lock adjusting too! 1 2 Tools E-tools Drawings of E-tools Measurements on all drawings are given in mm unless other- wise indicated. E1750, Differential lock adjusting tool soo _ 10 E1750 g Qo |? ‘a 27 62) = BRB © 30 x @ 8 x 2 (To be welded in the hole) * = to be punched into the material 0:39