Articulated Haulers A35C Volvo / A35C Volvo BM Service Repair Manual
Complete repair service manual with electrical wiring diagrams for Articulated Haulers A35C Volvo / A35C Volvo BM, with technical information to maintain, diagnose, repair, and service like professional mechanics.
Articulated Haulers A35C Volvo / A35C Volvo BM workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
Articulated Haulers A35C Volvo Service Repair Manual.pdf
MAIN SECTIONS
0 - GENERAL
1 - STANDARD PARTS, SERVICE
2 - ENGINE WITH MOUNTING AND EQUIPMENT
3 - ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
4 - POWER TRANSMISSION
5 - BRAKE
6 - STEERING
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPM.; MISC EQUIPM
PRODUCT DETAILS:
Pages: 994
File Format: PDF (Windows & Mac & Linux)
Language: English
TABLE OF CONTENTS
0 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Description......4
03 - SPECIFICATIONS......6
Brake and compressed air system......6
Capacities-......9
Capacities......10
Dimensions......11
Electrical system......14
Engine......16
Filter change, intervals......20
Hydraulic system......21
Oil and fluid change, intervals......23
Power transmission......24
Product identification plates......26
Steering system......27
Tightening torques......28
Weights......37
07 - STANDARD TIME......39
Time Guide......39
08 - TOOL......48
Drawings of E-tools that can be made in your own workshop......48
Recycling station FRS-10GS......70
Scales 981 2444......72
Special tools for the drivetrain......73
1 - STANDARD PARTS, SERVICE......76
16 - LUBRICANT; FUEL; OTHER FLUID......77
Hydraulic oil, sampling......77
Recommended lubricants......78
17 - SERVICE......80
Cleanliness, brake and hydraulic systems......80
Electric welding......81
Recovering......83
Towing of machine......84
Troubleshooting......86
2 - ENGINE WITH MOUNTING AND EQUIPMENT......87
20 - GENERAL......88
Description......88
Diagnosis using service display unit ......89
Specifications, general (serial no. 5201 –, US 60301–)......90
Specifications, general (serial no. –5200,......91
Specifications, tightening torques-[4526]......92
Specifications, weights......94
Troubleshooting ......95
21 - ENGINE......96
Compression check, engine at operating temperature......96
Engine and transmission, mounting......98
Engine and transmission, removing......101
Engine, mounting......108
Engine, removing......113
Specifications, capacities......123
Specifications, general......124
Valves, adjusting......125
22 - LUBRICATING SYSTEM......127
Description-......127
Specifications, general-[3726]......130
Specifications, general-[3757]......131
Specifications, weights-[3647]......132
23 - FUEL SYSTEM......133
Automatic timing adjuster (alpha adjuster)......133
Automatic timing adjuster, checking......135
Feed pressure, checking......140
Fuel system, bleeding air......141
Injection timing, checking and adjusting......143
Injectors, changing......148
Low and high idle speed, checking and adjusting with service display unit......152
Low emission engines......155
Specifications, capacities-[3401]......157
Specifications, general-[2913]......158
Specifications, general-[3054]......159
Specifications, general-[3224]......160
Specifications, general-[3433]......161
Stall speed, checking with service display unit......162
25 - INLET & EXHAUST SYSTEM......164
Functional description ......164
Specifications, general-[2636]......165
Specifications, general-[2730]......166
Specifications, weights ......167
Specifications, weights-[2837]......168
26 - COOLING SYSTEM......169
Checking function......169
Coolant pump, removed, reconditioning......171
Coolant, changing......178
Description ......181
Fan drive, description......185
Fan motor, adjusting speed......187
Fan motor, reconditioning......189
Hydraulic motor and hydraulic pump for fan,......194
Radiator, adjusting......196
Radiator, changing......198
Specifications, capacities ......201
Specifications, general-[1840]......202
Specifications, general-[2158]......203
Specifications, general-[2420]......204
Specifications, tightening torques ......205
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......206
30 - GENERAL......207
Charging of batteries......207
Codes used in wiring diagrams......208
Electrical symbols......219
Electrical system and instruments......223
Explanations of wiring diagrams......224
Special instructions for servicing the electrical system......226
Specifications, general-[1511]......227
31 - BATTERY......228
Specifications, General ......228
32 - ALTERNATOR; CHARGE REGULATOR......229
Alternator, changing......229
Specifications, general-[1402]......231
33 - STARTING SYSTEM......232
Specifications, general-[1258]......232
Starter motor, changing......233
35 - LIGHTING......234
Headlights, alignment......234
Headlights, changing light bulb......235
Specifications, general-[1159]......236
37 - CABLE; FUSE; RELAY......237
Circuit 1 (serial no. 5201–, US 60301–)......237
Circuit 1 (serial no. –5200, US –60300)......241
Circuit 10 (serial no. 5201–, US 60301–)......244
Circuit 10 (serial no. –5200, US –60300)......247
Circuit 11, spare (serial no. 5201–, US 60301–)......250
Circuit 11, spare (serial no. –5200, US –60300)......252
Circuit 12 (serial no. 5201–, US 60301–)......254
Circuit 2 (serial no. 5201–, US 60301–)......258
Circuit 2 (serial no. –5200, US –60300)......262
Circuit 3 (serial no. 5201–, US 60301–)......266
Circuit 3 (serial no. –5200, US –60300)......269
Circuit 4 (serial no. 5201–, US 60301–)......272
Circuit 4 (serial no. –5200, US –60300)......275
Circuit 5 (serial no. 5201–, US 60301–)......278
Circuit 5 (serial no. –5200, US –60300)......281
Circuit 5 cont’d. (serial no. 5201–, US 60301–)......285
Circuit 5 cont’d. (serial no. –5200, US –60300)......288
Circuit 6 (serial no. 5201–, US 60301–)......291
Circuit 6 (serial no. –5200, US –60300)......294
Circuit 6 cont’d. (serial no. 5201–, US 60301–)......297
Circuit 6 cont’d. (serial no. –5200, US –60300)......300
Circuit 7 (serial no. 5201–, US 60301–)......303
Circuit 7 (serial no. –5200, US –60300)......306
Circuit 8 (serial no. 5201–, US 60301–)......309
Circuit 8 (serial no. –5200, US –60300)......312
Circuit 9 (serial no. 5201–, US 60301–)......315
Circuit 9 (serial no. –5200, US –60300)......319
Connectors, cables (serial no. 5201–, US 60301–)......322
Connectors, cables (serial no. –5200, US –60300)......351
Connectors, illustrations......376
Fuses and relays in left electrical distribution box......380
Left electrical distribution box......382
Other fuses and relays......384
Right electrical distribution box (serial no. 5201–, US 60301–)......386
Right electrical distribution box (serial no. –5200, US –60300)......388
Specifications, general ......390
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......391
Combination instrument (serial no. –4915,......391
Contronic Information display unit......393
Contronic Service display unit......395
Diagnosis using service display unit-[4525]......397
Information display unit, displays......400
Information display unit, summary......406
Operator information......407
Other instruments and operating controls......408
Other operating controls (serial no. –5200,......410
Right instrument panel-[5023]......412
Right instrument panel......414
Sensor for retarder temperature (SE13), measuring resistance......416
Service display unit, displays......417
Service display unit, summary......430
Speedometer, electric, calibrating......431
Speedometer, electric, changing......432
Speedometer, electronic, description......434
Speedometer, electronic, programming instructions......438
4 - POWER TRANSMISSION......443
40 - GENERAL......444
Checking main, torque converter and lubrication oil pressure......444
Description-[4003]......449
Pressure checks......451
41 - CLUTCH; TORQUE CONVERTER......454
Specifications, weights-[3901]......454
42 - TRANSMISSION; HYDRAULIC CONTROL......455
Clutches, brakes and solenoids......455
Component and description......456
Diagnosis using service display unit-[3543]......460
Gearshifting control system......462
Measuring resistance of solenoids......463
Missing signal from both engine speed sensor (SE3) and speed sensor (SE4)......468
Missing signal from engine speed sensor (SE3)......469
Other causes of malfunction......470
Retarder valve, changing seal......472
Specifications, capacities-[3825]......473
Specifications, general-[3252]......474
Specifications, general-[3707]......475
Specifications, tightening torques-[3759]......476
Specifications, weights-[3733]......477
Transmission PT1761......478
Transmission retarder valve, adjusting air pressure......479
Transmission, checking resistance of solenoids......480
Transmission, clutches and brakes......487
Transmission, mounting downward through door opening......489
Transmission, mounting–upward......493
Transmission, removing upward......500
Transmission, removing–downward......507
Troubleshooting chart......514
Troubleshooting-[2745]......521
Turbine speed sensor, changing......522
43 - GEARBOX......525
Checking and adjusting longitudinal differential lock – from underneath......525
Dropbox, changing seal for front output shaft......528
Dropbox, changing seal for input shaft......529
Dropbox, changing seal for rear output shaft......531
Dropbox, mounting......532
Dropbox, removing......536
General......540
Sensors for high and low range, adjusting......546
Specifications, capacities-[2202]......548
Specifications, general-[2045]......549
Specifications, tightening torques-[2136]......550
Specifications, weights-[2111]......551
45 - PROPELLER SHAFT......552
Propeller shaft between transmission and......552
Propeller shaft for front bogie axle, changing......554
Propeller shaft for rear bogie axle, changing......557
Propeller shaft in frame joint, changing......559
Propeller shaft, front output shaft......560
Specifications, tightening torques-[2010]......562
Specifications, weights-[1944]......564
46 - FRONT AXLE; REAR AXLE......565
Dog clutch 6x6, checking and adjusting......565
Hub, changing seals......569
Specifications, capacities-[1150]......570
Specifications, capacities-[1320]......571
Specifications, capacities-[1444]......572
Specifications, general-[1059]......573
Specifications, general-[1221]......574
Specifications, general-[1351]......575
Specifications, general-[1537]......576
Specifications, tightening torques-[1628]......577
Specifications, weights-[1125]......579
Specifications, weights-[1247]......580
Specifications, weights-[1417]......581
Specifications, weights-[1602]......582
Transverse differential lock, adjusting......583
49 - MISCELLANEOUS......587
Transmission, hydraulic diagram......587
5 - BRAKE......590
50 - GENERAL......591
Description-[0904]......591
Specifications, tightening torques-[0832]......594
51 - WHEEL BRAKE......595
Brake caliper, changing......595
Brake caliper, reconditioning......599
Brake discs, changing......603
Brake pads for service brake, changing......611
Specifications, general-[0618]......615
52 - HYDRAULIC BRAKE SYSTEM......616
Accumulator, checking......616
Brake pads for service brake, checking......621
Brake pump, changing piston rings......624
Brake pump, changing......630
Brake system, bleeding and filling oil (serial no. –5200, US –60300)......632
Brake system, bleeding and filling oil......638
Brake system, changing brake oil and-[0436]......643
Brake system, changing brake oil and......647
Brake system, checking function......651
Foot brake valve, changing......655
Foot brake valve, reconditioning (removed)......658
Foot brake valve, setting......660
Foot brake valve......663
Relay valves......666
Specifications, capacities-[0158]......668
Specifications, general-[0132]......669
Specifications, general-[5527]......670
Specifications, general-[5831]......671
Unloading valve and non-return valve block, removing and mounting......672
Unloading valve, functional description......675
55 - PARKING BRAKE......677
Automatic adjustment lever......677
Brake pads, changing......679
Description-[5406]......682
Parking brake caliper, removed, reconditioning......689
Parking brake valve, reconditioning (removed)......691
Parking brake, changing brake caliper......694
Specifications, general-[5009]......698
Specifications, general-[5200]......699
Specifications, weights-[5226]......700
Spring brake cylinder, changing......701
Spring brake cylinder, removed, reconditioning......704
Spring brake cylinder......706
56 - COMPRESSED-AIR BRAKE......708
Air compressor......708
Anti-freeze reservoir......711
Compressor, removing and mounting......712
Cut-out and cut-in pressure, checking, adjusting......714
Description-[4933]......715
General repair instructions, compressor......718
Lubrication of pressure regulator (removed)......719
Pressure regulator......721
Pressure retaining valve......724
Safety valve, wet tank......726
Specifications, capacities-[4605]......727
Specifications, general-[4353]......728
Specifications, general-[4446]......729
Specifications, general-[4540]......730
59 - MISCELLANEOUS......731
Compressed air diagram (serial no. 5201–, US 60301–)......731
Compressed air diagram (serial no. –5200, US –60300)......733
Compressed air system, position list (serial no. 5201–, US 60301–)......735
Compressed air system, position list (serial no. –5200, US –60300)......737
Hydraulic diagram (serial no. 5201–, US 60301–)......739
Hydraulic diagram (serial no. –5200, US –60300)......741
Hydraulic system, position list (serial no. –5200, US –60300)......743
Hydraulic system, position list (serial no. 5201–, US 60301–)......744
Retarder, functional description-[4006]......745
Retarder, functional description......747
Specifications, general-[3918]......749
6 - STEERING......750
60 - GENERAL......751
Description-[3837]......751
Specifications, general-[3805]......753
64 - STEERING......754
Damping cylinder, changing seals......754
Damping cylinder, checking pre-load......756
Description-[3730]......758
Max. oil pressure, hydraulic system (steering and dumping), checking and adjusting......764
Secondary steering, adjusting operating pressure and stand-by (hold) pressure......767
Specifications, general-[3124]......770
Specifications, general-[3652]......771
Specifications, tightening torques-[3215]......772
Specifications, weights-[3150]......773
Steering cylinder, changing seals......774
Steering cylinder, changing......779
Steering linkage, changing roller bearing in bracket (serial no. 4738–)......783
Steering linkage, changing roller bearing in front lever (serial no. 4738)–......788
Steering linkage, changing roller bearing in rear lever (serial no. 4738–)......794
Steering linkage, checking and adjusting......799
Steering valve complete with connections......805
Steering valve, changing......811
Steering valve, removed, reconditioning......813
Steering, rack and pinion gear, changing......818
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT......821
71 - FRAME......822
Description-[2740]......822
Load unit frame, checking dimensions......825
Specifications, tightening torques-[2634]......828
Specifications, weights-[2602]......832
72 - SUSPENSION......833
Description......833
Rubber spring, changing......834
74 - FRAME LINK......836
Frame joint, changing brass bushing (metallic bearing) in torque tube......836
Frame joint, checking and adjusting clearance......842
Frame joint, removed, changing brass bushing (metallic bearing)......846
Frame joint, removed, changing wear rings on hitch......847
Specifications, weights-[2224]......850
Steering joint spherical bearings, checking clearance......851
Steering joint, changing spherical bearings and pivot pins......853
75 - AXLE SUSPENSION......866
Bogie beam, changing rubber bushing (one side)......866
Bogie beam, changing rubber spring (one side)......871
Front or rear torsion bar, adjusting (load unit)......873
Torsion bar rubber bushing (rubber bearing), changing......874
77 - WHEELS; TRACKS; TYRE; HUB; DRUM......876
Specifications, weights-[1850]......876
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE......877
81 - CAB, NAKED; CANOPY......878
Specifications, general-[1744]......878
Specifications, weights-[1810]......879
82 - ENGINE HOOD; MUDGUARD; FOOT STEP......880
Specifications......880
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING......881
Window pane, changing......881
85 - CAB INTERIOR; UPHOLSTERY......883
Air spring for operator’s seat, changing......883
Maintenance instructions......885
Operator’s seat, adjusting height of attachment......886
Operator’s seat, air suspension......887
Operator’s seat, mechanical spring suspension......888
87 - AIR CONDITIONING UNIT......889
Air conditioning, checking function......889
Fan motor, changing......891
Functional description......893
Heat control valve, changing......895
Heater, changing......897
Refrigerant R134a, draining......899
Refrigerant R134a, vacuum pumping including filling (charging)......903
88 - INTERIOR EQUIPMENT......908
Protection against electromagnetic interference......908
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS......911
90 - GENERAL......912
Diagnosis using service display unit......912
Hydraulic diagram, complete (steering,......914
Hydraulic system (steering, dumping and fan drive)......917
Troubleshooting......920
91 - WORKING HYDRAULIC; SERVO HYDRAULICS......921
Hydraulic pump and dumping valve, description-[0312]......921
Hydraulic pump and dumping valve, description......936
Hydraulic pumps for steering and dumping system, checking internal leakage......951
Hydraulic system, bleeding-[0718]......954
Hydraulic system, bleeding-[0736]......955
Hydraulic system, bleeding......956
Non-return valve block, right......957
Oil pump, ground dependent, changing......959
Specifications, capacities-[0545]......961
Specifications, capacities-[0637]......962
Specifications, capacities......963
Specifications, general-[0010]......964
Specifications, general-[0028]......965
Specifications, general-[0338]......966
Specifications, general-[0504]......967
Specifications, general-[0611]......968
Specifications, weights-[0123]......969
Specifications, weights-[0411]......970
Stand-by pressure (hold pressure), disconnected and connected signal line......971
95 - LOAD CARRIER......975
Dumping system, description-[5926]......975
Dumping system, description-[5944]......977
Dumping system, description......979
Dumping valve, removing and mounting......981
Hoist cylinder......984
Load body, adjusting against frame......986
Load body, changing dump bearing......988
Specifications, general......992
Specifications, tightening torques......993
Specifications, weights......994
Articulated Haulers A35C Volvo / A35C Volvo BM Service Repair Manual
