Volvo Skid Steer Loaders MCT135D Repair Service Manuals
Volvo Skid Steer Loaders MCT135D Repair Service Manuals
Complete official service manual with Electrical Wiring Diagrams for Volvo Skid Steer Loaders MCT135D, with all the shop information to maintain, diagnostic, repair, refurbish/rebuild like professional mechanics.
Volvo Skid Steer Loaders MCT135D 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.
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
File Format: PDF (1,089 pages, bookmarked, Searchable, Printable, high quality)
Language: English
Printable: Yes
TABLE OF CONTENTS - Expanded View
0 - GENERAL
03 - SPECIFICATIONS
Conversion tables
Hydraulic connections, tightening torques
Push lock fittings
Quick release couplings
Thread locking compound, application_specifications
Tightening torque, specifications
07 - STANDARD TIME
Operation numbers for additional work
1 - STANDARD PARTS, SERVICE
16 - LUBRICANT; FUEL; OTHER FLUID
Fuel, lubricant and filling capacities
17 - SERVICE
Alternator, checking
Arrival Inspection, according to Inspection Programme
Battery isolator switch, checking
Battery terminals, cleaning
Cab heating and air conditioning filter, replacing
Coolant, changing
Coolant level, checking
Coolers, cleaning
Cooling system integrity, checking
Crankcase ventilation separator element, replacing
Cylinder rams condition, checking
Delivery Inspection, according to Inspection Programme
Engine air cleaner primary filter, replacing
Engine air cleaner secondary filter, replacing
Engine air cleaner system integrity, checking
Engine belt condition, checking
Engine oil and filter, changing
Engine oil level, checking
Exhaust system integrity, checking
Fuel filter, replacing
Hydraulic oil, changing
Hydraulic oil filters, replacing
Hydraulic oil level, checking
Hydraulic oil tank breather filter, replacing
Leakage, checking
Lubrication, every 10 hours
Maintenance of Stored Machines, according to Inspection Programme
Maintenance service, every 1000 hours
Maintenance service, every 10 hours
Maintenance service, every 1500 hours
Maintenance service, every 2000 hours
Maintenance service, every 3000 hours
Maintenance service, every 500 hours
Maintenance service, every 50 hours
Spark arrester, cleaning
Starter motor, checking
Track sprocket bolt torque, checking
Track tension and condition, checking
Tyre wear and air pressure, checking
Water separator, checking
Water separator filter, replacing
Wheel nuts torque, checking
Wiring harness integrity, checking
19 - GENERAL
Before operating
Before service, read
Checklist after a fire or heat exposure
Cleanliness
Decontamination
Electrical system
Environmental handling for the future
Environment
General
Health hazards with paint, plastics and rubber
Safety concerns everybody!
Safety when handling oil and fuel
Safety when handling the machine
Safety when working with batteries
Service position
Some simple rules regarding tyre handling
2 - ENGINE WITH MOUNTING AND EQUIPMENT
20 - GENERAL
Engine belt, replacing
21 - ENGINE
Big end bearing, checking
Big end bearing, replacing
Camshaft, specifications
Connecting rod, checking
Crankcase, specifications
Crankshaft, checking
Crankshaft gear, replacing
Crankshaft main bearing, replacing
Crankshaft position sensor, description
Crankshaft pulley, replacing
Crankshaft, replacing
Crankshaft, specifications
Cylinder compression, testing
Engine, component locations
Engine, description
Engine, installing
Engine mounts, replacing
Engine, removing
Engine rotation speed sensor (camshaft), replacing
Engine rotation speed sensor (crank shaft), replacing
Engine, specifications
Engine timing gears, description
Flywheel gear ring, replacing
Flywheel, replacing
Oil sump, description
Oil sump, replacing
Pistons, description
Rocker assembly, description
Rocker assembly, disassembling and assembling
Rocker levers, rocker shaft and tappets, specifications
Tappet cover, replacing
Tappets, replacing
Valves, replacing
22 - LUBRICATING SYSTEM
Lubrication oil pressure, checking
Lubrication system, specifications
Oil cooler, description
Oil cooler, disassembling and assembling
Oil cooler, replacing
Oil pump, description
Oil pump, replacing
23 - FUEL SYSTEM
Fault tracing, fuel system
Fuel injection pump, description
Fuel injection pump gear, replacing
Fuel injector, testing
Fuel pipes, description
Fuel pump, replacing
Fuel pump, specifications
Fuel rail pressure, checking
Fuel rail, replacing
Fuel system, bleeding
Fuel system, description
High pressure fuel pipes, replacing
Injection pump, replacing
Injectors, replacing
Injectors seal, replacing
Low pressure fuel pipes, replacing
25 - INLET & EXHAUST SYSTEM
Exhaust manifold, replacing
Inlet and exhaust system, specifications
Inlet manifold, replacing
Turbocharger, checking
Turbocharger, description
Turbocharger, replacing
Variable geometry turbocharger (VGT) actuator, replacing
Variable Geometry Turbocharger (VGT), description
Variable geometry turbocharger (VGT), replacing
26 - COOLING SYSTEM
Belt tensioner, replacing
Coolant pump, description
Coolant pump, replacing
Coolant temperature sensor, description
Cooling fan solenoid, replacing
Cooling package, installing
Cooling package, removing
Cooling system, description
Cooling system, specifications
Expansion tank, replacing
Fan control valve, description
Fan control valve, installing
Fault tracing, cooling system
Thermostat, checking
Thermostat, description
27 - ENGINE CONTROL
Accelerator pedal, replacing
Cold start advance solenoid, replacing
Electronic throttle control, description
Engine control unit (E-ECU), description
29 - MISCELLANEOUS
EGR cooler, replacing
Exhaust Gas Recirculation (EGR), description
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
30 - GENERAL
Collection of basic data
Electrical system, specifications
Fault code list
Lead and connector checks
Logic control
Multimeter
31 - BATTERY
Battery, description
Battery, installing
Battery maintenance
Battery, removing
Battery, specification
32 - ALTERNATOR; CHARGE REGULATOR
Alternator, description
Alternator, disassembling and assembling
Alternator removing, inspecting and installing
Alternator, specifications_(2600)
Alternator, specifications_(2611)
Alternator, specifications
33 - STARTING SYSTEM
Starter motor, description
Starter motor, disassembling and assembling
Starter motor removing, inspecting and installing
35 - LIGHTING
Direction indicator, replacing
Road lights, description
Work lights, description
Work lights, replacing_{01-22-26}
Work lights, replacing_{01-22-39}
36 - OTHER ELECTRICAL EQUIPMENT
Back up alarm, replacing
Hand throttle control switch, description
Radio, specifications
White noise_reverse alarm, description
Windscreen wiper front motor, replacing
Windscreen wiper, replacing
Windscreen wiper system, description
Windscreen wiper tank fluid, changing
Windscreen wiper tank, replacing
37 - CABLE; FUSE; RELAY
Battery disconnect switch, replacing
Battery isolator
Explanation of wiring diagrams
Wiring diagram 10
Wiring diagram 11
Wiring diagram 1
Wiring diagram 2
Wiring diagram 3
Wiring diagram 4
Wiring diagram 5
Wiring diagram 6
Wiring diagram 7
Wiring diagram 8
Wiring diagram 9
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
Coolant temperature sensor, replacing
Engine oil pressure sensor, replacing
Engine oil pressure switch, replacing
Engine oil temperature sensor, replacing
Exhaust manifold pressure sensor, replacing
Exhaust manifold temperature sensor, replacing
Hourmeter, replacing
Intercooler outlet temperature sensor, replacing
Knock sensor, description
Knock sensor, replacing
Temperature and manifold air pressure (TMAP) sensor, replacing
Temperature and mass airflow (TMAF) sensor, replacing
4 - POWER TRANSMISSION
42 - TRANSMISSION; HYDRAULIC CONTROL
Transmission pilot solenoid, replacing
Transmission solenoid, replacing
Transmission solenoids, description
44 - HYDROSTATIC DRIVE
Drive chain, description
Drive chain, installing
Drive chain, removing
Driveline, description
Drive motor adapter, replacing
Drive motor, installing
Drive motor, specification
Pump coupling, installing
Pump coupling, removing
Pump_engine coupling, description
Tensioner_recoil unit, specifications
Transmission pump, adjusting
Transmission pump, description
Transmission pump, disassembling and assembling
Transmission pump, installing
Transmission pump, removing
Transmission pump, restoring
Transmission pump, specifications_(0358)
Transmission pump, specifications
46 - FRONT AXLE; REAR AXLE
Drive motor, disassembling and assembling
Wheel hub assembly, replacing
Wheel hub condition, checking
Wheel hub, description
5 - BRAKE
55 - PARKING BRAKE
Parking brake, assembling
Parking brake, description and operation
Parking brake, disassembling
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
71 - FRAME
Stop pad, adjusting
Stop pad, installing
Stop pad, removing
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
Drive sprocket, installing
Drive sprocket, removing
Front idler wheel, disassembling and assembling
Front idler wheel, installing
Front idler wheel, removing
Guide roller, disassembling and assembling
Guide roller, installing
Guide roller, removing
Rear idler wheel, disassembling and assembling
Rear idler wheel, installing
Rear idler wheel, removing
Recoil unit, disassembling and assembling
Recoil unit, replacing
Rubber track, description
Rubber track, inspecting
Rubber track, installing
Rubber track, removing
Rubber track, repairing
Track frame, installing
Track frame, removing
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
81 - CAB, NAKED; CANOPY
Cab, installing
Cab, removing
Operator's protective structure, description
Operator's station, introduction
83 - DOORS; HATCH; COVER PLATE, (all)
Cab door hinge, installing
Cab door hinge, removing
Cab door, installing
Cab door, removing
Cabin door, description
Door handle, replacing
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING
Side mirror, installing
Side mirror, removing
Window pane, installing
Window pane, removing
Window, preparing
Windows, description
85 - CAB INTERIOR; UPHOLSTERY
Seat, replacing
86 - PROTECTIVE EQUIPMENT
Door guard, replacing
87 - AIR CONDITIONING UNIT
Air conditioning, component location
Air conditioning, description
Air conditioning, specifications
Air conditioning unit, general
Compressor, description
Expansion valve, description
Fault tracing, HVAC
HVAC, discharging and pressurizing
Refrigerant pipe, description
Water valve, description
Water valve, replacing
Wiring diagram, HVAC
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS
90 - GENERAL
Boom suspension system accumulator (BSS), specifications
Boom suspension system (BSS) valve block, specifications
Charge pump, specifications
Fault tracing on hydraulic system
Hydraulic service procedures
Hydraulic system, bleeding
Hydraulic system, description
Hydraulic system, flushing
Joystick control, replacing_(3222)
Joystick control, replacing
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
Accumulator, description
Accumulator, replacing
Accumulator, specifications
Attachment bracket, operating_{12-21-55}
Attachment bracket, operating_{12-22-04}
Auxiliary hydraulic pressure, releasing
Boom suspension system accumulator, charging and discharging
Boom suspension system valve, description
Boom suspension system valve, replacing
Explanations to hydraulic diagram
Fault tracing on hydraulic system_{12-22-46}
Fault tracing on hydraulic system_{12-22-56}
Gear pump, description
Gear pump, disassembling and assembling
Gear pump, replacing
Gear pump, specifications
High flow solenoid, description
Hydraulic cylinder, description
Hydraulic cylinders, specifications
Hydraulic diagram 1_{12-29-14}
Hydraulic diagram 1_{12-29-26}
Hydraulic oil tank, replacing
Hydraulic oil temperature sensor, description
Hydraulic pressure sensor, description
Hydraulic pressure sensor, replacing
Hydraulic return line filter, specification
Hydraulic tank, description
Hydraulic tank, specifications
Load sensing valve block, specifications
Self level valve, description
Self level valve, replacing
Self level valve, specifications
Smooth ride system, description
Smooth ride system solenoid, replacing
Smooth ride system valve, replacing
92 - MECHANICAL EQUIPMENT_ATTACHMENT
Attachment bracket cylinder, installing
Attachment bracket cylinder, removing
Attachment bracket, installing
Attachment bracket, removing
Loader Arm, Inspection
Loader arm lift ram, description
Loader arm lift ram, installing
Loader arm lift ram, removing
94 - UNIT, LOAD HANDLING
Loader arm implement pilot solenoid, description
Loader arm implement pilot solenoid, replacing
Loader arm, installing
Loader arm pivot pin, replacing
Loader arm, removing
Loader arm solenoid, replacing
Loader arm solenoids, description
Loader arm taper pin, adjusting
