VOLVO A40F Articulated Dump Truck Full Service Repair Manual

Service Information Document Title: Function Group: Information Type: Date: Safety concerns everybody! 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Safety concerns everybody! Always follow the instructions in the machine's operator's manual, which is a supplement to this Service Manual. The Operator's Manual must always be kept in the cab for easy reference. Volvo designs and manufactures machines with a high level of safety as well as effectiveness. All this work may be wasted if anyone who is about to perform service on any of our machines does not read the safety instructions, or does not follow them, e.g., does not replace guards, climbs on slippery machine parts instead of using a ladder, grabs a hold of hoses instead of handles or uses the wrong tools for the job. In order to maintain safe and effective function, always use the intended and adapted spare parts for the machine. Using genuine Volvo spare parts is recommended since they are adapted to the machine for highest safety and quality. Machines seldom cause accidents, instead people often do. A safety-conscious person and a well-maintained machine make for a safe, effective and profitable combination. Those who do not follow the safety instructions and observe the warnings in this manual must make sure that their work method is safe. Otherwise, there is a great risk of accidents, perhaps even accidents that result in fatalities. WARNING WARNING SYMBOL This symbol is shown at various points throughout the manual. The appearance of it means "Warning, stay alert! Your safety may be involved!" Get to know the capacity and limits of your machine!

Service Information Document Title: Function Group: Information Type: Date: Safety when handling the machine 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Safety when handling the machine Volvo Construction Equipment Group is only responsible if:       the machine has been used correctly and has been maintained according to recommendations in the service manuals and the machine's Operator's manual. prescribed service and inspections have been performed at the specified intervals. lubricant recommendations in the manual have been followed. no safety seals have been opened by an unauthorized person. all modifications and repairs have been performed in the manner prescribed by Volvo. only genuine Volvo parts/accessories, or attachments that fulfil Volvo's requirements have been used. WARNING Machine operators must have sufficient skills and knowledge of the content in the Operator's Manual before operating the machine. It is important that the operator reads and follows the instructions in the machine's Operator's Manual. An untrained operator may cause serious injuries and fatalities. Never operate a machine for which there is no Operator's Manual available. Learn to understand the warning plates, symbols and operating instructions for the machine before you start operating. A few safety rules General         Repair malfunctions or defects that affect safety as soon as possible. Always wear a hard hat, protective goggles, gloves, work shoes and other safety items that your work requires. Avoid standing in front of or behind the machine, and on or under the machine when the engine is running. To avoid unnecessary climbing on the machine, use a window scraper or brush with long handle when cleaning external window glass or rear-view mirrors. When servicing the machine, i.e. changing light bulbs, a ladder may be needed. Make sure that stepping surfaces, service areas, handles and slip-protection are clean and free from oil, diesel fuel, dirt and ice and that they're replaced if they are defective or missing. Check at regular intervals that all slip-protection is firmly attached. If not, these shall be attached or replaced. Always face the machine and use the steps and handrails when entering or leaving the machine. Use two hands and one foot, or two feet and one hand. Do not jump!

Figure 1 Entering/leaving the machine Figure 2 Read the Operator's manual, plates and instructions before you operate the machine. Before operating         Read the Operator's manual before you operate the machine! Follow the instructions for operating and perform the indicated recommended actions before operating. Some important rules below: Perform a control light test before starting the engine by turning the ignition key to position 1 (see Operator's manual). Perform all safety checks prescribed in the Operator's manual. WARNING Never operate the machine if you are tired or under the influence of alcohol, medicine or other drugs. Before starting the engine indoors, make sure that ventilation is adequate for this. The machine is equipped with a diesel engine and the exhausts may be hazardous to your health. Therefore, ensure adequate ventilation and avoid running the engine more than necessary where ventilation is inadequate. Read all plates and instructions on the machine and in the Operator's manual before you operate or perform service on the machine. Each one of these contains important information regarding safety, handling and service. Always sit in the operator's seat when you start the engine. Use the lap type seat belt during all operation. The machine must be fully functional before it's put into operation, that is, all defects that may cause eventual accidents must have been repaired.

  Never operate the machine for long periods without ventilation, or with a completely closed cab without the fan on (to avoid lack of oxygen). Step only on the prepared non-slip surfaces and use the provided handles and rails. Hip-type seatbelt       Use the seat belt during all operation. Figure 3 Use the seat belt during all operation If the seatbelt needs washing: Use a mild soap solution when washing and let the belt dry while it's fully pulled out before it's rolled up. Make sure that the belt is installed correctly. Replace the seatbelt immediately if it's worn, damaged or the machine has been involved in an accident where the belt had to take some strain. Modifications of the belt or its mountings is never permitted. The hip-type seatbelt is intended for one adult, not more. Always keep the belt rolled up when not in use. When the engine is running     Respecter symbols and alarm displays. The red alarm displays require immediate action or consideration, see instructions in the Operator's Manual under information display unit. Move the gear selector to neutral position and apply the parking brake before leaving the machine. WARNING Risk of crushing injuries Do not stand near the frame joint unless it has been locked with the frame joint lock. Stop the engine before you leave the machine unattended. The cab is the operator's protection and meets the standards for roll-over protection according to test standards, (ROPS), see further . Prerequisite for protection is that the operator uses the lap-type seat belt and 191 CE-marking, EMC-directive remains in the cab in case of a roll-over. Therefore, hold on to the steering wheel if the machine rolls over. Do not jump! The cab is dimensioned to fulfill the requirements for objects falling on to the cab roof according to given test methods (that is, FOPS, see further ). 191 CE-marking, EMC-directive Alternative exit

Figure 4 1. 2. Alternative exit (right side of cab) Hammer Alternative exit is possible through the split side window in front of the B-pillar on both the right and left sides of the cab. Alternative exits are marked with a decal. In an emergency situation the window glass can be broken using the hammer. When the window glass has been broken, the moulding between the window's two parts falls away. NOTE! It is only possible to break windows marked with decal for alternative exit. Figure 5 The hammer is used in emergencies to:   break the window glass for alternative exits, cut the seatbelt with the knife located in the rear edge of the hammer.

Service Information Document Title: Function Group: Information Type: Date: Service position 1 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Service position 1 Op nbr 191-021 88830046 Dump body support Figure 1 1. Place the machine on firm and level ground. 2. Apply the parking brake. WARNING Risk for personal injury caused by crushing. The machine could turn. Lock the steering lock. WARNING Risk of crushing.

An unlocked raised dump body can fall down. Personnel standing under a falling dump body could be seriously injured, including death. Always lock the dump body before entering under it. 3. Lock the steering joint with the steering joint lock. Lower the load body against the frame or elevate the load body and secure with the load body lock or 88830046 Dump body support. 4. During on-going service work, fasten a warning sign on the steering wheel with information that service is in progress. 5. Turn off the engine and remove the start key. 6. Block the wheels in a suitable manner (i.e. with wedges). 7. Depressurize pressurized lines and pressure tanks. See and 520 Brake system, relieve pressure . 900 Hydraulic system, relieve pressure 8. Allow the machine to cool down.

Service Information Document Title: Function Group: Information Type: Date: Checking function 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Checking function After work in a safety-related electrical system, a function check shall be performed to meet the requirements in ISO 15998. Safety-related electrical system Systems covered by function check for safety-related electrical system are:   Parking brake. For check, see . 550 Parking brake, function check Load and dump brake. For checking, see . 553 Load and Dump brake, function check

Service Information Document Title: Function Group: Information Type: Date: Safety when working with air conditioning refrigerant 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Safety when working with air conditioning refrigerant WARNING There are a number of safety aspects that should be kept in mind when working with repairs and maintenance of the air conditioning. Therefore, read and consider the safety section in the Service Manual Air Conditioning R134a before starting any work. For repairs of the air conditioning, refer to the Service Manual Air Conditioning R134a.

Service Information Document Title: Function Group: Information Type: Date: Safety when lifting and supporting the machine 191 Service Information 2014/7/7 0 Profile: ART, A40F (37535) [GB] Safety when lifting and supporting the machine       When lifting or supporting machine parts, use equipment with a lifting capacity that equals at least the weight of the part in question. All lifting devices, such as straps, slings, ratchet blocks, must comply with governing national regulations for lifting devices. We will not accept any responsibility if any lifting devices, tools or work methods are used other than those described in this publication. If a jack is to be used, make sure that the ground or floor is even and is sufficiently firm or strong to support the expected load. Prevent the machine from rolling by applying the parking brake and placing suitable wedges on both sides of the wheels which are not to be raised off the ground. Always use a jack with sufficient lifting capacity and position it under the axle or on the inside of the wheel that is to be removed. Make sure that the jack is correctly positioned and is at the correct angle to the lifting point on the machine. Take care to position supports under the machine in a safe way.

VOLVO A40F Articulated Dump Truck Full Service Repair Manual

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