Articulated Haulers A35E Volvo / A35E FS Volvo Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Articulated Haulers A35E Volvo, A35E FS Volvo, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions Articulated Haulers A35E, A35E FS 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 A35E Volvo, A35E FS Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,002 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description ...4
Product identification plates...6
Information and warning decals...8
03 - SPECIFICATIONS...11
Tightening torques...12
Capacities...23
Machine dimensions...24
Weights...28
Rocker arm shaft; tightening torques_{39-48}...29
Rocker arm shaft; tightening torques_{39-33}...30
Coolant with anti-freeze and corrosion protection; recommendation...32
Tightening torques; valve cover ...34
Power take-off; tightening torque ...35
Tyre equipment and recommended tyre pressures...37
Lubrication system; specifications...39
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...40
Recovering and towing...41
Lifting machine...43
07 - STANDARD TIME...46
Operation numbers for additional work...47
08 - TOOL...49
E-1763...50
E-2000...52
E-2500...54
E-2501...56
E-2502...58
E-2503...60
E-2506...61
E-2507...62
E-2511...63
E-2518...65
E-2519...67
E-2520...69
E-2524...71
E-2538...78
E-2548...80
Infrared Thermometer...82
88830051 User Instruction...86
09 - MISCELLANEOUS...96
Troubleshooting; Heneral...97
Troubleshooting strategy ...98
Troubleshooting; assistant devices...101
Collection of basic data...102
VCADS Pro service tool; general...105
VCADS Pro; Test...107
VCADS Pro; Error codes...109
VCADS Pro; Calibrating...111
VCADS Pro; Programming...113
VCADS Pro tests...116
Basic checks...120
Engine; basic check...122
Electrical system; basic check ...126
Power transmission; basic check...130
Brake system; basic check...132
Parking brake; basic check...135
Steering and hydraulics; basic check...137
1 - STANDARD PARTS; SERVICE...139
11 - STANDARD PARTS...140
Service ...141
16 - LUBRICANT; FUEL; OTHER FLUID...142
Recommended lubricants...143
Alternative fuels...145
17 - SERVICE...148
Service...152
Safety when servicing...153
Arrival Inspection; according to Inspection Programme...155
Delivery Inspection; according to Inspection Programme...156
Maintenance of Stored Machines; according to Inspection Programme...157
Warranty inspection...158
Warranty inspection 100 hours...159
Warranty inspection 1000 hours...161
Maintenance service; daily...163
Maintenance service; every 50 hours...164
Maintenance service; every 250 hours...165
Maintenance service; every 500 hours...166
Maintenance service; every 1000 hours...168
Maintenance service; every 2000 hours...170
Maintenance service; every 4000 hours...173
Maintenance service; every 6000 hours...176
Maintenance service; every 12000 hours_{15-51}...179
Maintenance service; every 12000 hours_{15-35}...182
Condition test and maintenance program...185
Test-run and check...187
MATRIS; reading; export reading...188
VCADS Pro; logged errors; read off...189
Alternative exit; checking...190
Fuel; coolant and oil leakage; check...192
Brake pipes and hoses; check...193
Coolant's freezing point; check...194
Belts and belt tension; check; replace when needed...195
Battery; charging state; electrolyte level; cables and connections; especially connections at starter motor; check...196
Engine mounts_dropbox mounts_propeller shafts; bolted joints and flange mounts; check torques...198
Axle mounts; bolted joints; tourque; check...201
Tyres; wear and air pressure; checking...202
Cab; air pre-cleaner filter; clean_change...203
Cab; prefilter; replace...205
Cab main filter; replacing...206
Cab; asbestos filter; replacing...207
Engine; air cleaner; cover; clean...208
Engine; air pre-cleaner; check_clean...209
Engine; air cleaner; main filter; replace. EON (option) only replace when indicated...211
Engine; air cleaner; secondary filter; replace. EON (option) only when indicated...212
Fuel system; extra fuel pre-filter; drain...214
Fuel system; extra fuel pre-filter; change...216
Fuel filters; primary and secondary filter; replace...218
Oil-bath air cleaner's reservoir (optional equipment); oil; check...220
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change...222
Oil-bath air cleaner's reservoir (optional equipment); filter insert; clean...224
Engine; oil and filter; change...225
Power take-off suction strainer; cleaning...227
Fuel tank; sediment; drain. Shorter interval as needed...229
Transmission; oil; main oil filter and lubrication oil filter; replace...231
Dropbox; oil; replace...234
Frame joint oil; check...236
Frame joint oil; change...237
Radiator; clean (from fan side with compressed air)...239
Condenser; clean (with compressed air) (optional equipment)...240
Air drier; drier cartridge; replace...241
Cooling fan; return oil filter; replacing...242
Brake system; pressure oil filter; replace...243
Drive axles; oil; change...245
Brake cooling oil; level; check...248
Brake cooling oil tank; oil; change...249
Brake cooling oil tank; return oil filter; replace and magnetic rods; clean...251
Hydraulic oil tank; oil; replace if system is filled with mineral oil or Volvo Biodegradable hydraulic oil 46. If system is filled with other biologically degradable hydraulic oil; replace every 2000 hour...253
Hydraulic oil tank; return oil filter; replace; and magnetic rods; clean...255
Fuel tank; hydraulic oil tank; brake cooling oil tank; breather filter; replace...257
Drive axles; transmission; dropbox and frame joint; breather filter; replace...259
Service brake; brake disc wear; check...262
Parking brake pads; check...265
Steering cylinder bearings; clearance; check...266
Load body; rubber cushions; clearance; check...268
Front frame; rear section; cracks; checking...269
Steering joint bearings; first check of steering joint bearings after 6000 hours. Thereafter every 2000 hours...270
Frame joint bearings; clearance; check...272
Valve clearance and IEGR; double rocker arms; check_adjust...274
Accumulator; checking...275
FS-cylinder; rubber bearings; check; after first 4000 hours; then after every 1000 hours...276
Load body; exhaust heated; check_clean_grease...277
Automatic central lubrication; filter; cleaning_replacing...280
Dropbox quick drain valve; replacing_{50-57}...282
Dropbox quick drain valve; replacing_{49-27}...285
Lubrication; see lubrication chart...287
Service journal (included in Operator's manual); fill in...288
Coolant; changing ...289
Dump body alternative; lowering-45...294
Dump body alternative; lowering ...296
Parking brake; manually releasing ...298
Transporting the machine...300
19 - GENERAL...302
Cleanliness; brake and hydraulic systems...304
Refrigerant for air conditioning...305
CE-marking; EMC-directive...306
Safety concerns everybody!...310
Safety when handling the machine...314
Service position 3_{29-05}...318
Service position 2_{26-18}...324
Checking function...328
Safety when lifting and supporting the machine...330
Safety when using lifting equipment...332
Rules when handling tyres...334
Safety when working with batteries...337
Starting with booster batteries...339
Safety when handling oils and fuel...340
Safety when working on pressurized systems...341
Safety when working on hydraulic systems...343
Safety when handling accumulators_{01-04}...345
Safety when handling accumulators_{59-56}...346
Safety when working on the machine's electrical system...347
Safety during electric welding...348
Fire prevention measures...349
Checklist after a fire or heat exposure...352
Health hazards with paint; plastics and rubber...355
Environment...358
Environmental handling for the future...360
Waste handling...362
Environmentally safe handling...366
Environmentally hazardous fluids...368
Safety when working with air conditioning refrigerant...371
Working in environmentally contaminated areas...374
Decontamination...377
2 - ENGINE WITH MOUNTING AND EQUIPMENT...381
20 - GENERAL...382
Engine; description...383
Engine Protection...385
Tightening torques; engine mounts...387
Engine; capacities...389
Engine; identification...390
E-ECU MID 128 pre-programmed; replacing...392
E-ECU MID 128 non-programmed; replacing...394
21 - ENGINE...397
Engine; general specifications...399
Cylinder compression; PC test...401
Engine and transmission; removing...402
Engine and transmission; installing...422
Engine rotation speed sensor; replacing...442
Engine rotation speed sensor (camshaft); replacing...449
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...455
Cylinder compression; testing...461
Tightening torques; valve cover...470
Tightening torque; cylinder head...471
Cylinder head; description...472
Cylinder block; description...474
Oil trap; description...477
Cylinder liner; description...480
Pistons; description...482
Valve system; specification...483
Valve mechanism; double rocker arm...484
Rocker arm shaft; tightening torques_{33-58}...485
Rocker arm shaft; tightening torques_{33-05}...486
Valve mechanism; description...488
Adjusting; general...490
Internal Exhaust Gas Recirculation (IEGR); description...492
Valves; adjusting...498
Valve cover; removing...505
Valve cover; installing...508
Engine transmission; specification...513
Engine timing gear; description...516
Camshaft; description...518
Camshaft setting; checking...519
Camshaft; replacing...529
Timing gear case new gasket; installing...548
Crank mechanism; description...559
Flywheel; tightening torques...561
Crankshaft rear oil seal; replacing...562
Oil sump; tightening torque...569
Oil level sensor; replacing...571
Oil sump gasket; replacing...578
Engine mount rubber cushion; replacing...585
Engine mounting rear; changing...589
22 - LUBRICATING SYSTEM...593
Lubrication system; description_{11-50}...594
Lubrication system; description_{10-57}...595
Lubrication system; specifications...596
Lubrication oil pressure; checking with pressure gauge...597
Oil cooler; tightening torques ...599
Oil cooler; replacing...602
23 - FUEL SYSTEM...606
Fuel system; tightening torques...607
Fuel system; description...608
Fuel flow; description...611
Air in fuel system; checking...614
Carbon dioxide in fuel system; checking...618
Fuel feed pump; specifications_{52-46}...624
Fuel feed pump; specifications_{52-04}...625
Fuel feed pump; description...626
Feed pump pressure; checking...629
Fuel filter housing; description...631
Fuel pump; inspecting...634
Fuel pump (valves); inspecting...639
Fuel system; bleeding...641
Feed pressure; PC test...643
Fuel tank; volume...644
Stall speed; checking...645
Unit injectors; specifications...648
Unit injectors; description...649
Unit injector pretension; adjusting...652
Unit injector; replacing...654
Injector shut off; manual...663
Overflow valve; checking...664
Injector sleeves; replacing...667
25 - INLET & EXHAUST SYSTEM...675
Air intake and filter...676
Charge-air cooling...677
Exhaust pressure governor...678
Turbocharger; description...679
Turbocharger; specifications...682
Turbocharger; inspecting...683
Turbocharger; replacing...686
Air cleaner; preheating coil; specifications...691
Air cleaner; description...692
Preheating coil; replacing...693
Intercooler; specifications...696
Intercooler; description...697
Charge air cooler; replacing...699
Fan pump; Removing...707
Fan pump; Installing...708
Cooling fan motor; charge air cooler; checking_adjusting low rpm...709
Cooling fan motor; charge air cooler; checking_adjusting high rpm...713
Hydraulic cooling fan control; PC test...717
26 - COOLING SYSTEM...718
Cooling system; tightening torques...719
Cooling unit; description...721
Cooling system; principle illustrations...722
Cooling system; flushing...726
Cooling system specifications...731
Radiator; description...733
Radiator; removing...734
Radiator; installing...741
Radiator; adjusting...748
Coolant; changing...750
Thermostat; specifications...755
Thermostat; description...756
Coolant pump; description...758
Secondary coolant pump; replacing...760
Thermostat; replacing ...766
Cooling fan speed control; description...771
Fan belt and_or alternator belt; checking and adjusting tension...773
Fan pump; removing...776
Fan pump; installing...777
Cooling fan motor; radiator; checking_adjusting low rpm...778
Cooling fan motor; radiator; checking_adjusting high rpm...782
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...786
30 - GENERAL...787
Electrical system; special instructions for servicing; electronic components...797
Electrical system; special instructions for servicing; electrical components; batteries...800
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{59-50}...802
Electrical system; special instructions for servicing; electrical components; alternator and charging regulator_{59-00}...804
Electrical system; special instructions for servicing; action when working on machine...806
Service connection and programming connection...808
Software versions and ECUs_part number; general...810
Software versions and ECUs_part number; checking...812
Software versions and ECUs_part number; list...815
Machine status hardware_software...819
Data links; fault tracing with Oscilloscope...820
Electrical system; specifications...830
Control units; voltage supply...832
Data bus system...834
General vehicle electronics...835
2F4203; gearshifting strategy transmission...837
2F4204; control of transmission...840
2F4205; retarder control...843
2F4206; turbine speed; transmission...844
2F4207; slipping discs; transmission...846
2F4208; oil level in transmission...848
2F4209; oil temperature in transmission...850
2F4210; lubrication oil pressure in transmission...852
2F4211; output speed; transmission...854
2F4212; overspeeding engine; transmission...856
2F4214; slipping discs; lock-up...857
2F4215 transmission; overspeeding...859
2F4216; input speed; transmission...861
2F4217; lock-up control...862
2F4218 transmission; solenoid valve defective...864
2F4220; range speed...866
2F4221; oil pressure control...867
2F4222; engine torque offset...869
3F2701; engine acceleration; applied throttle value...870
3F2702; applied throttle value; limitation...871
3F8301; door open...873
4F2701; operating speed engine...875
5F5201; output pressure brakes...878
5F5202; brake pressure in accumulator...880
5F5501; parking brake...882
5F5901; load and dump brake...885
6F2301; main fuel filter...887
6F2302; fuel level in tank...888
6F2303; fuel consumption...890
6F2304; water in fuel...892
6F2305; fuel pressure...893
7F4601; activation of differential locks and 6–wheel drive...894
8F3801; language and unit selection...896
8F3802; date and time...898
8F3803; display unit lighting_display...900
8F3804; instrument lighting...902
8F3805; Inactive warnings_error codes; reset...903
8F3806; Inactive warnings_error codes; reset...904
9F2501; preheating induction air...906
9F2504; air filter...908
10F5204 brake cooling oil; level in tank...909
10F9101; engine-dependent steering pressure; hydraulics...911
10F9102; ground-dependent steering pressure; hydraulics...913
10F9103 hydraulic oil; level in tank...916
10F9105; hydraulic oil; temperature...918
10F9109; hydraulic pump; control...920
11F4001; Automatic Traction Control (ATC)...921
12F2601; coolant temperature...926
12F2602; cooling system; regulation current control...928
12F2603; coolant level...933
12F2604; brake cooling oil; circulation...934
13F3201; system voltage...938
13F3202; charging monitoring...940
14F3303; delayed stop; engine...942
15F3801; inclination indication...944
17F3801; machine hours...945
17F3802; tachograph...947
17F3803; machine distance...948
17F3804; machine hours; correction...949
17F3805; machine distance; correction...950
17F9501; travelled distance; operating hours and number of cycles...951
18F2201; engine oil pressure...953
18F2202; engine oil level...955
18F2203; engine oil temperature...957
19F3701; bus communication reduced...959
19F3702; bus communication open circuit...960
20F2502; request engine brake...962
20F4202; retarder activation...963
20F5201; brake lights...965
20F2503; engine brake; activation...966
20F5901; wheel retarder; pedal request...968
20F5902; wheel retarder; activation...969
21F2701; engine On_Off...971
21F2702; starter motor...973
21F2703; stop engine...975
21F3301; start electronics...976
21F3302; stop electronics...978
21F3304; safety stop...980
22F8501; seat belt; check...981
24F9901; theft protection...983
25F9101 Warning; dump lever not in float position...985
25F9102 Warning; dump lever not in hold position...986
25F9501 Warning; body up...988
25F9502; work cycle start...990
26F3601; windshield washer...991
26F3603; windshield wiper interval...992
27F7201; hydraulic suspension; calibration...993
27F7202; hydraulic suspension; positioning...995
28F2701; engine speed...998
28F2702; idle speed...1000
28F2703; engine speed monitoring...1001
28F4301; vehicle speed_distance...1003
28F4302 Exceeded speed limit...1005
28F4201 transmission overspeeding...1006
30F4201; back-up alarm and back-up light...1007
30F4202; gearshift selector...1008
30F4203; shift lock-out (hold)...1010
30F4204; start 2nd gear...1012
31F3601; buzzer central warning...1013
31F3801; orange central warning...1014
31F3802; red central warning...1015
31F3803; red extra central warning...1016
31F3804; external activation of red central warning...1017
31F3805; external activation of orange central warning...1018
31F3806; external activation of buzzer central warning...1019
32F3807; information display unit; display outside temperature...1020
32F5201; Display unit; brake cooling oil temperature...1021
35F9901 Parameter list...1022
35F9901 Parameters; MO3 module acceleration...1024
35F9901 Parameters; MO4 module power take-off...1026
35F9901 Parameters; MO6 module fuel...1027
35F9901 Parameters; MO8 module display setting...1028
35F9901 Parameters; MO9 module inlet system...1030
35F9901 Parameters; MO10 module oils; pressures...1031
35F9901 Parameters; MO11 module Automatic Traction Control (ATC)...1033
35F9901 Parameters; MO14 module delayed stop...1035
35F9901 Parameters; MO18 module engine oil...1036
35F9901 Parameters; MO20 module retardation...1037
35F9901 Parameters; MO22 module operator's seat...1038
35F9901 Parameters; MO24 module theft protection...1039
35F9901 Parameters; MO25 module dump lever...1040
35F9901 Parameters; MO26 module wipers_washing windshield...1041
35F9901 Parameters; MO27 module hydraulic suspension...1042
35F9901 Parameters; MO28 module speeds (rpm)...1044
35F9901 Parameters; MO30 module gear selector...1046
35F9901 Parameters; MO31 module warnings...1047
35F9901 Parameters; MO37 module service...1048
37F3801; service interval machine...1050
V2007.3.0; change specification...1052
V2007.4.0; change specification...1053
V2007.5.0; change specification...1054
V2007.6.0; change specification...1055
V2008.1.0; change specification...1056
V2008.3.0_V2008.3.1; change specification...1058
V2008.4.0; change specification...1059
V2009.4.0; change specification...1060
Software design...1061
Troubleshooting strategy...1064
Troubleshooting; general...1066
Error codes; build-up...1067
SAE J1708 (Information bus)...1072
SAE J1939_ CAN-bus (control bus)...1074
Error detection...1076
Error code and warning levels...1077
Error causes...1080
Error codes; showing...1084
Electrical cabling and connectors; checking...1086
Measuring; general...1091
Measuring symbols; description...1093
Component descriptions...1097
Electronic control system; special tool measuring; general...1101
Electronic control system; special tool measuring; E–ECU...1103
Electronic control system; special tool measuring; I-ECU...1105
Electronic control system; special tool measuring; T-; V- and V2-ECU...1107
Electronic control system; special tool measuring; transmission PT...1108
Electronic control system; special tool measuring; component...1110
Electrical system; basic check...1112
MID 128 PID 158 Battery voltage; description and measuring...1113
HE2501; description and measuring...1115
MA2301–MA2306; description and measuring...1116
MA2502; description and measuring...1118
MA2504; description and measuring...1120
MA4601-MA4603; description and measuring...1122
MA4604; description and measuring...1124
MA4604_MA4607; description and measuring...1126
MA5501; description and measuring_{46-34}...1128
MA5501; description and measuring_{44-45}...1130
MA5501_MA5502; description and measuring_{42-49}...1132
MA5901; description and measuring...1134
MA7601-MA7608; description and measuring...1137
MA9101; description and measuring...1139
MID 128 SID 211 5 V feed to engine sensors 2; description and measuring...1141
MID 128 SID 230 IVS; description and measuring...1142
MID 128 SID 232 5 V feed to engine sensors 1; description and measuring...1144
MO3301; description and measuring...1145
PWM2501; description and measuring...1147
PWM2601_PWM2602; description and measuring...1149
PWM4201; description and measuring...1151
PWM4203; description and measuring...1153
PWM4205-PWM4212; description and measuring...1155
PWM5201; description and measuring...1157
PWM5901; description and measuring...1159
PWM9102; description and measuring...1161
RE2501; description and measuring...1163
RE3704; description and measuring...1165
RE3801; description and measuring...1167
RExxxx; Relays general; description and measuring...1169
SAE J1708_1587 information link; description and measuring...1171
SAE J1939_CAN control link; description and measuring...1173
SE2202; description and measuring...1175
SE2203; description and measuring...1177
SE2205; description and measuring...1179
SE2301; description and measuring...1181
SE2302; description and measuring...1183
SE2303; description and measuring...1185
SE2501; description and measuring...1187
SE2502; description and measuring...1189
SE2507; description and measuring...1191
SE2508; description and measuring...1193
SE2509; description and measuring...1195
SE2601_SE2602; description and measuring...1197
SE2603; description and measuring...1199
SE2606; description and measuring...1201
SE2607; description and measuring...1203
SE2701; description and measuring...1205
SE2702; description and measuring...1207
SE2703; description and measuring...1209
SE3201; description and measuring...1211
SE3801; description and measuring...1213
SE3802; description and measuring...1215
SE4201; description and measuring...1217
SE4202; description and measuring...1219
SE4203; description and measuring...1221
SE4208; description and measuring...1223
SE4212; description and measuring...1225
SE4213; description and measuring...1227
SE4214; description and measuring...1229
SE4215; description and measuring...1231
SE4218; description and measuring...1233
SE4219; description and measuring...1235
SE4307; description and measuring...1237
SE4309; description and measuring...1239
SE4310; description and measuring...1241
SE4311; description and measuring...1243
SE4607; description and measuring...1245
SE4608; description and measuring...1247
SE5201_SE5202; description and measuring...1249
SE5203_SE5204; description and measuring...1251
SE5207; description and measuring...1253
SE5214; description and measuring...1255
SE5215-SE5217; description and measuring...1257
SE5501; description and measuring...1259
SE5901; description and measuring...1261
SE6403; description and measuring...1263
SE7601-SE7606; description and measuring...1265
SE7607-SE7610; description and measuring...1267
SE8301; description and measuring...1269
SE8501; description and measuring...1271
SE8502; description and measuring...1273
SE8701; description and measuring...1275
SE9102_SE9103; description and measuring...1277
SE9104; description and measuring...1279
SE9105; description and measuring...1281
SE9501; description and measuring...1283
SWxxxx; description and measuring...1285
SW3301; description and measuring...1287
SW3801; description and measuring...1289
SW5501; description and measuring_{00-42}...1291
SW5501; description and measuring_{59-01}...1293
SW5501; description and measuring_{57-46}...1295
SW5901; description and measuring...1297
SW7601; description and measuring...1299
31 - BATTERY...1301
Battery; description...1302
Battery; specifications...1303
Battery; charging...1304
Batteries; replacing...1306
32 - ALTERNATOR; CHARGE REGULATOR...1313
Alternator; specifications...1314
Alternator; tightening torques...1316
Alternator; description...1318
Alternator; replacing incl function checking...1319
33 - STARTING SYSTEM...1322
Starter motor; specification...1323
Starter motor; tightening torques...1325
Starter motor; replacing...1327
Cold-start device; specifications...1329
35 - LIGHTING...1330
Lighting; specifications...1331
Headlights; adjusting...1333
Working lights; description...1337
36 - OTHER ELECTRICAL EQUIPMENT...1338
Windscreen wiper motor; tightening torques...1339
Windscreen wiper front motor; replacing...1340
Connectors; position...1353
Connectors; overview...1359
Control unit; description...1366
I-ECU MID 140 non-programmed; replacing...1368
I-ECU MID 140 pre-programmed; replacing...1372
T-ECU; MID 130; changing non-programmed ECU...1373
T-ECU; MID 130; changing pre-programmed ECU...1378
V-ECU MID 187 non-programmed; replacing...1379
V-ECU MID 187 pre-programmed; replacing...1389
V2-ECU; MID 249; replacing non-programmed ECU...1390
V2-ECU; MID 249; replacing pre-programmed ECU...1394
Tech Tool; programming of machine...1395
37 - CABLE; FUSE; RELAY...1397
Electrical symbols and designations...1399
Explanation of wiring diagrams...1404
Wiring diagrams_{26-20}...1407
Wiring diagrams_{26-04}...1409
Wiring diagram A01...1410
Wiring diagram A02_{25-00}...1412
Wiring diagram A02_{24-36}...1414
Wiring diagram A03_{24-08}...1416
Wiring diagram A03_{23-47}...1418
Wiring diagram A04_{23-18}...1420
Wiring diagram A04_{22-57}...1423
Wiring diagram A05_{22-28}...1426
Wiring diagram A05_{22-08}...1429
Wiring diagram A06...1432
Wiring diagram A07_{59-17}...1435
Wiring diagram A07_{58-54}...1438
Wiring diagram A08...1441
Wiring diagram A09_{57-48}...1444
Wiring diagram A09_{57-22}...1447
Wiring diagram A10...1450
Wiring diagram A11_{56-16}...1453
Wiring diagram A11_{55-52}...1456
Wiring diagram A12...1459
Wiring diagram A13...1462
Wiring diagram A14...1465
Wiring diagram A15...1468
Wiring diagram A16...1471
Wiring diagram A17...1473
Wiring diagram A18_{52-09}...1475
Wiring diagram A18_{51-45}...1478
Wiring diagram A18_{51-18}...1480
Wiring diagram A19...1482
Wiring diagram A20...1484
Wiring diagram A21_{49-36}...1486
Wiring diagram A21_{49-11}...1489
Wiring diagram A21_{48-51}...1492
Wiring diagram A22...1494
Wiring diagram A23 ...1497
Wiring diagram A24...1500
Wiring diagram A25...1502
Wiring diagram A26...1504
Wiring diagram A27...1507
Wiring diagram A28...1509
Wiring diagram A31...1511
Wiring diagram A32...1513
Wiring diagram A33_{42-26}...1516
Wiring diagram A33_{41-55}...1519
Wiring diagram A34_{41-16}...1522
Wiring diagram A34_{40-57}...1524
Electrical distribution box; description...1526
Grounding points; frame connections...1530
Components; list and positions...1532
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...1540
Instruments and controls; overview...1541
Instruments and controls; left instrument panel...1543
Instruments and controls; main instrument...1545
Instruments and controls; right instrument panel...1548
Instruments and controls; climate control panel...1550
Instruments and controls; control panel...1551
Group 1; service screens...1553
1.0 Setting to zero; service interval machine...1556
1.0.1 Engine oil; monitoring change interval...1558
1.0.1 Acknowledgement; change of engine oil...1560
1.0.2 Transmission oil; monitoring change interval...1562
1.0.2 Acknowledgement; change of transmission oil...1564
1.1_ 1.2 Error code screens; general...1566
1.3_1.4 Saved error codes_warnings...1568
1.3_1.4 Setting to zero; saved error codes_warnings...1570
Warning screens; cab...1572
Service display unit; general...1574
Initial display and settings...1576
Operating information and service...1580
Engine...1583
Electrical system...1586
Transmission...1591
Axles and brakes...1594
Hydraulics...1596
Digital input and output signals...1597
Service display unit; summary...1603
39 - MISCELLANEOUS...1605
Rear view monitor; service menu...1606
CareTrack system; description...1611
CareTrack antenna; replacing...1613
4 - POWER TRANSMISSION...1621
40 - GENERAL...1622
Hydraulic transmission; capacity...1623
Dropbox; capacities...1624
Front axle_rear axle; capacities...1625
Drivetrain; description...1626
42 - TRANSMISSION; HYDRAULIC CONTROL...1628
Hydraulic diagram PT - Image...1629
Hydraulic transmission; specifications...1631
Transmission oil pressure; specifications...1633
Transmission; tightening torques...1636
Transmission; cut-away drawing...1640
Description...1642
Hydraulic diagram PT_{05-38}...1650
Hydraulic diagram PT_{05-17}...1653
Transmission; removing...1657
Transmission; installing...1675
Transmission; removing from a non mounted engine_{57-35}...1691
Engine and transmission; removing_{57-08}...1695
Engine and transmission; installing_{56-44}...1696
Transmission; installing on a non mounted engine_{56-29}...1697
Seal for rear output shaft; replacing...1700
Induction sensor for output shaft; replacing...1708
Induction sensor for turbine speed; replacing...1711
Checking of main; torque converter and lubricating oil pressure...1716
PWM-valve control system; replacing...1720
43 - GEARBOX...1727
Transfer gearbox; description_{51-36}...1728
Transfer gearbox; description_{51-12}...1735
Dropbox; component location...1738
Dropbox; specifications...1745
Dropbox; tightening torque...1746
Dropbox; removing...1748
Dropbox; installing...1757
Differential lock dropbox sender unit; adjustment...1766
Checking and adjusting the longitudinal differential lock...1771
Dropbox seal for front otput shaft; replacing...1773
Dropbox seal for rear output shaft; replacing...1782
Rotation speed sensor; replacing ...1789
45 - PROPELLER SHAFT...1793
Propeller shaft; description...1794
Propeller shaft; tightening torque...1796
Intermediate shaft and_or bearing; replacing (in frame joint)...1798
46 - FRONT AXLE; REAR AXLE...1824
Axles; specifications_{37-52}...1825
Axles; specifications_{37-34}...1828
Drive axles; description...1830
Axles; tightening torques...1831
Repair instruction; general...1834
Centre gear ; removing and installing...1836
Input shaft seal; Replacing...1847
Hub reduction; removing...1852
Centre gear; replacing ...1858
Output shaft 6-wheel drive; sealing and bearing; replacing...1874
Dog clutch for drive to rear bogie axle; checking and adjusting...1892
Input shaft seal; replacing ...1906
Rotation speed sensor; replacing...1911
Rotation speed sensor; adjusting...1915
Hub reduction; installing...1921
Centre gear; replacing...1939
Input shaft seal; replacing...1950
ATC; description...1955
Transverse differential lock_axle; checking and adjusting...1960
48 - POWER TAKE OFF...1965
Power outlet; specifications...1966
Power take-off; tightening torque...1968
Power take-off; between engine and gearbox; reconditioning...1970
49 - MISCELLANEOUS...2006
Oil cooler; tightening torques...2007
Oil cooler; replacing_{19-03}...2009
Oil cooler; replacing_{18-06}...2018
5 - BRAKE...2027
50 - GENERAL...2028
Compressed air diagram - Image...2029
Hydraulic diagram; brake system - Image...2032
Brakes; specifications...2035
Brake system; specifications...2036
Accumulator; specification ...2038
Compressed-air system; specifications...2039
Brake cooling system; specification...2041
Braking system; description...2042
Compressed air system; description...2043
Pressure check connections; description_{12-42}...2044
Pressure check connections; description_{12-25}...2045
Hydraulic diagram; brake system_{12-00}...2047
Hydraulic diagram; brake system_{11-42}...2051
Hydraulic diagram; brake system_{11-25}...2055
Compressed air diagram_{11-00}...2059
Compressed air diagram_{10-43}...2063
Compressed air diagram_{10-25}...2067
51 - WHEEL BRAKE...2071
Wear indicator; adjusting...2072
Wheel brake; function description_{09-04}...2077
Component description_{08-39}...2085
Wheel brake; replacing...2088
Brake discs; replacing...2089
52 - HYDRAULIC BRAKE SYSTEM...2090
Brake cooling oil system; diagram - Image...2091
Hydraulic brake system; pressure build-up...2092
Brake system; bleeding...2093
Brake system; pressure releasing...2098
Brake system hydraulic function; checking...2100
Pressure check connections; description ...2105
Brake cooling system; specification_{04-27}...2106
Brake cooling system; specification_{04-11}...2107
Hydraulic pump brake cooling; specification...2108
Brake cooling oil system; description...2109
Brake cooling oil system; diagram...2113
Brake cooling circulation function; checking...2117
Foot brake valve; description...2118
Foot brake valve; replacing...2121
Accumulator; replacing_{00-00}...2124
Accumulator; replacing_{59-37}...2127
Hydraulic pump; max working pressure; checking and adjusting ...2131
Hydraulic pump; replacing...2135
Accumulator (removed) charging pressure; checking...2136
Accumulator; discarding ...2138
55 - PARKING BRAKE...2141
Parking brake; description...2142
Parking brake; manually releasing...2143
Parking brake; function description_{56-19}...2145
Parking brake; function description_{56-00}...2148
Parking brake; specifications...2151
Parking brake; tightening torque...2153
Parking brake; replacing brake disc...2155
Spring brake cylinder; replacing...2166
Parking brake ; replacing brake caliper...2176
Parking brake brake pads; replacing...2188
Parking brake function; checking...2195
Load and dump brake; description_{50-00}...2197
Load and dump brake; description_{49-43}...2201
Load and dump brake working pressure; checking and adjusting...2204
Load and Dump brake servo pressure; checking...2207
Load and Dump brake function; checking...2209
56 - COMPRESSED-AIR BRAKE...2210
Relief_Cut-in pressure; checking...2211
Relief_Cut-in pressure; adjusting...2213
Compressor; replacing...2215
Quick coupling compressed air; replacing...2224
59 - MISCELLANEOUS...2228
Retarder; description...2229
Retarder pedal; description...2234
PWM5901; description...2236
6 - STEERING...2238
60 - GENERAL...2239
Steering system; description...2240
Troubleshooting tips ...2242
Steering system; specifications...2244
64 - STEERING...2245
Pressure build-up; engine-dependent pumps; description ...2246
Steering gear; specifications...2249
Steering gear; checking and adjusting...2251
Steering gear; replacing...2255
Steering linkage; tightening torque...2264
Steering linkage; checking and adjusting...2266
Steering times; checking and adjusting...2271
Steering valve neutral position; checking and adjusting...2273
Steering cylinder; specifications...2277
Steering cylinder; description...2278
Steering cylinder; removing...2280
Steering cylinder; installing...2285
Steering cylinder removed; reconditioning excl replacing bearings...2290
Steering cylinder bearings; replacing_{33-39}...2300
Steering cylinder bearings; replacing_{33-21}...2303
Damping cylinder; specification...2309
Damping cylinder...2310
Damping cylinder; checking spring force...2312
Damping cylinder seal; changing...2316
Secondary steering hydraulic pump; removing...2321
Secondary steering hydraulic pump; installing...2324
Secondary steering working and stand-by pressure; adjusting...2327
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...2332
71 - FRAME...2333
Frame; description...2334
Protecting plate; description...2336
Protective plate; weight...2338
Protective plate; removing...2340
Protective plate; installing...2351
72 - SUSPENSION...2361
Accumulator; specification...2363
Accumulator; description...2364
Full Suspension; description...2366
Relieve pressure...2374
Hydraulic suspension; Forced motion...2376
Manual lowering_{23-55}...2378
Manual lowering_{23-36}...2381
Hydraulic suspension; function check...2382
Full Suspension; bleeding air...2388
Full Suspension accumulator; discarding...2389
Full Suspension accumulator; overhauling...2391
Suspension system hydraulic cylinder; overhauling...2394
Suspension system hydraulic cylinder bushing; replacing_{20-55}...2408
Suspension system hydraulic cylinder bushing; replacing_{20-38}...2413
Position sensor; complete replacing...2416
Suspension cylinder FS; specifications...2419
Accumulator precharge pressure; checking and adjusting ...2420
Accumulator; removing...2426
Accumulator; installing...2430
Suspension cylinder; removing...2435
Suspension cylinder; installing...2440
Position sensor front; replacing...2445
Accumulator bank; removing...2448
Accumulator bank; installing...2452
Accumulator; removing_{13-49}...2455
Accumulator; removing_{13-31}...2458
Accumulator; installing_{13-02}...2461
Accumulator; installing_{12-45}...2464
Accumulator precharge pressure; checking and adjusting...2468
Suspension cylinder; description...2473
Suspension cylinder; removing_{11-24}...2475
Suspension cylinder; removing_{11-05}...2481
Suspension cylinder; installing_{10-36}...2485
Suspension cylinder; installing_{10-14}...2490
Position sensor rear; replacing...2496
74 - FRAME LINK...2499
Hitch; specifications_{08-35}...2500
Hitch; specifications_{08-18}...2504
Frame joint; tightening torques...2508
Capacities...2510
Frame joint; description...2511
Frame joint; measuring and adjusting clearence...2513
Frame joint; separating machine...2522
Frame joint; changing bearing; machine separated (on load unit frame)...2542
Articulated joint; checking clearence...2548
75 - AXLE SUSPENSION...2550
Axle suspension; tightening torque...2551
Tractor unit A-frame bushing; replacing...2554
Cross stay rubber bushing; replacing_{00-36}...2562
Cross stay rubber bushing; replacing_{00-21}...2564
A-frame bushing; rear on load unit; changing...2565
A-frame bushing; front on load unit; changing...2574
Cross stay rubber bushing; replacing_{58-10}...2581
Cross stay rubber bushing; replacing_{57-43}...2587
77 - WHEELS; TRACKS; TYRE; HUB; DRUM...2590
Wheel; tightening torque...2591
Wheel; removing...2593
Wheel; installing...2597
Wheel; aligning...2599
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...2603
80 - GENERAL...2604
Cabin; specification...2605
Cab description...2606
81 - CAB; NAKED; CANOPY...2607
Instructions for drilling in ROPS structure...2608
Cab; removing...2612
Cab; installing...2627
Cab; lifting points...2638
82 - ENGINE HOOD; MUDGUARD; FOOT STEP...2641
Hydraulic diagram; hood opening...2642
Engine hood; removing...2644
Engine hood; installing...2647
Electric hood pump; changing...2650
83 - DOORS; HATCH; COVER PLATE; (all)...2654
Door; replacing...2655
Cab door; removing door catch...2658
Cab door; installing door catch...2661
Door lock; replacing...2663
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...2667
Windows; general...2668
Door window; replacing...2670
85 - CAB INTERIOR; UPHOLSTERY...2675
Air suspension operator's seat; adjusting...2676
Air suspension for operator´s seat; changing...2678
Operator's seat; removing_{42-57}...2681
Operator's seat; removing_{42-42}...2682
Operator's seat; installing...2685
87 - AIR CONDITIONING UNIT...2686
Heater core; replacing...2687
Fan motor; replacing...2700
Heat control valve; replacing...2704
Heat control; replacing...2708
Thermostat; replacing...2710
Personal competence and accreditation...2713
Safety when working with air-conditioning refrigerant...2715
Repair instructions...2717
Air conditioning AC; basic principles...2719
Air conditioning unit; operation...2721
AC system; specifications...2724
Wiring diagram A23...2726
Air-conditioning; component location...2729
Refrigerant; draining...2730
Refrigerant; filling incl vacuum pumping...2731
Checking for leaks with inspection light...2732
Cooling unit; performance test...2734
Compressor; replacing incl draining and filling...2736
Evaporator; replacing incl draining and filling...2742
Receiver; replacing incl draining and filling...2752
Troubleshooting; air conditioning unit (AC)...2756
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...2758
90 - GENERAL...2759
Hydraulic main diagram - Image...2760
Hydraulic diagram; complete - Image...2762
Explanations to hydraulic diagram...2763
Hydraulic components; cleanliness when handling...2772
Hydraulic main diagram_{29-44}...2775
Hydraulic main diagram_{29-29}...2779
Hydraulic diagram; complete_{29-14}...2783
Hydraulic and servo systems; description...2787
Hydraulic oil; description...2788
Hydraulic oil; storing and handling...2790
Hydraulic system; repair of hydraulic components in workshop...2792
Hydraulic components; storing and transporting...2794
Troubleshooting tips...2796
Hydraulic system; bleeding...2798
Vacuum pump; connection...2799
Vacuum pump; disconnection...2802
Hydraulic system; relieve pressure...2803
Hydraulic system; description...2804
Pressure build-up; engine-dependent pumps; description...2806
Accumulator; discarding...2809
91 - WORKING HYDRAULIC; SERVO HYDRAULICS...2812
Hydraulic system; work instructions...2813
Pressure check connections; description...2815
Hydraulic tank; description...2818
Hydraulic system; capacities...2820
Steering and dumping valve; specifications...2821
Steering and dumping valve; tightening torques...2822
Steering and dumping valve; description...2824
Non-return valve function in steering and dumping valve_{22-39}...2828
Non-return valve function in steering and dumping valve_{22-24}...2829
Steering and tipping valve; removing...2830
Steering and tipping valve; installing...2839
Steering and dumping valve; removed; reconditioning_{20-34}...2848
Steering and dumping valve; removed; reconditioning_{19-54}...2867
Dump lever; changing...2886
Hydraulic pumps; specifications_{18-36}...2891
Hydraulic pumps; specifications_{18-21}...2894
Hydraulic pump; description...2897
Hydraulic pump flow regulation; description...2900
Proportional valve; description...2909
Working pumps; checking...2911
Hydraulic pump; standby pressure; checking and adjusting...2913
Hydraulic pump; max working pressure; checking and adjusting...2918
Pump; removing...2922
Pump; installing...2925
Pump regulator; checking...2929
Hydraulic pump (removed); changing shaft seal...2933
Dump lever; specifications...2936
Dump lever; description...2937
Dumping lever; checking pressure...2941
95 - LOAD CARRIER...2945
Dumping system; specification...2946
Hoist cylinder; specification...2947
Hoist cylinder; description...2948
Hoist cylinder; removing...2950
Hoist cylinder; installing...2954
Hoist cylinder bearing; changing_{11-22}...2958
Hoist cylinder bearing; changing_{11-03}...2964
Hoist cylinder removed; reconditioning...2969
Dump body; adjusting against frame...2978
Dump body joint; changing tipping bearing...2984
Cylinder; rear flap; gas pressure; checking and adjusting...2991
Dump body alternative; lowering...2995
99 - MISCELLANEOUS...2997
Hydraulic pressure; specifications...2998
Steering and dumping valve; overview illustration...3000
Articulated Haulers A35E Volvo / A35E FS Volvo Service Repair Manual
