Volvo EC35 Compact Excavators Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Volvo EC35 Compact Excavators, with all the shop information to maintain, diagnose, repair, and service like professional mechanics.
Volvo EC35 Compact Excavators 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
PRODUCT DETAILS:
Total Pages: 755 pages
File Format: PDF ( pages, bookmarked, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS - exploded view
0 - GENERAL
00 - DESCRIPTION; COMPLETE MACHINE
Caution sign - Diesel engine starting procedure
Caution sign - Emergency exit
Caution sign - Lashing
Caution sign - Lifting the machine
Caution sign - Operation and maintenance
Caution sign - Track tension
Identification of the engine EC 35, EC 45
Identification of the engine, from serial nr. EC 35 #283 18 963, EC 45 284 17 799
Machine identification
Position of components
Warning and information decals
Warning sign - Open engine hood only with engine stopped
Warning sign - Safety distance from the work area
00 - DESCRIPTION; COMPLETE MACHINE
03 - SPECIFICATIONS
Electrical system
ENGINE
Fuels, lubricants and filling capacities (litres)
Hydraulic motor 1 - travel system
Hydraulic system EC 35
Hydraulic system EC 45
Load capacity tables EC 35
Load capacity tables EC 45
Main dimensions EC 35
Main dimensions EC 45
Mechanical transmission - track gearbox
Plugs with tapered thread
Power transmission
Reach EC 35
Reach EC 45
Reach of the working attachment EC 35
Reach of the working attachment EC 45
Slewing ring, tightening torques
Strength class 10.9 Metric coarse and fine threads
Strength class 8.8 Metric coarse and fine threads
Tightening torques, engine
Tightening torques
UNC-threads, coarse pitch
03 - SPECIFICATIONS
07 - STANDARD TIME
Operation numbers for additional work
07 - STANDARD TIME
1 - STANDARD PARTS, SERVICE
16 - LUBRICANT; FUEL; OTHER FLUID
Alternative fuels
Recommended lubricants
16 - LUBRICANT; FUEL; OTHER FLUID
17 - SERVICE
Change engine oil, replace filter
Changing the hydraulic oil
Cleanliness, braking and hydraulic system
Creeping of hydraulic cylinder
Cylinder speed
Deviation when travelling straight ahead
Electric welding
Engine air filter unit
Hydraulic system, replacement of hydraulic filter element1
Inspection
Jump starting
Maintenance instructions
Measuring the play of the slewing bearing
Recharging of batteries
Repairing hydraulic system
Service and maintenance
Slewing overtravel
Swing speed
Track running speed
Travel gear, oil change
Travel Speed
17 - SERVICE
19 - GENERAL
General precautions
Move and operate machine safely
Preparations for work
Safety concerns everybody!
Safety measures during operation
19 - GENERAL
2 - ENGINE WITH MOUNTING AND EQUIPMENT
20 - GENERAL
Description
Engine, description
Maintenance standards
Periodic inspection and maintenance procedure
Periodic maintenance chart
Precautions
Special tools
Troubleshooting chart
20 - GENERAL
21 - ENGINE
Compression pressure inspection from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Compression pressure inspection
Cooling System
Cylinder block, disassembly and assembly
Cylinder head, disassembly_assembly
Engine, adjusting operation
Engine performance diagram (measuring values for one hour with fan)
Engine, specifications_{08-53-39}
Engine, tightening torques
Engine trouble shooting
Gear train and camshaft, disassembly and assembly
General information for EC 35 from serial nr.#283 18 963, EC 45 from serial nr.#284 17 799
General information for EC 35, till serial nr.#283 18 462; EC 45, till serial nr.#284 17 298
Installing the engine, from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Installing the engine
Removing the engine, from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Removing the engine
Specification, engine_{08-53-16}
Specification, engine_{08-53-27}
Specification, filling capacities
Specification, weight
Tightening torque
Tightening torques, engine
Valves, adjusting
Valves adjustment from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Valve timing
21 - ENGINE
22 - LUBRICATING SYSTEM
General information for EC 35 from serial nr.#283 18 963, EC 45 from serial nr.#284 17 799
Lubricating system, description
Lubricating system, description
Lubrication system, disassembly and assembly
22 - LUBRICATING SYSTEM
23 - FUEL SYSTEM
Adjustment of fuel injection pump
Assembling the fuel injection line
Bleeding the fuel system
Changing the fuel filter
Description
Disassembling the fuel injection line
Disassembling the fuel pump
Fuel injection nozzle from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Fuel injection pump, description
Fuel injection pump, disassembly and assembly
Idle speed, inspection and adjustment from serial nr. EC 35 283 18 963, EC 45 284 17 799
Idle speed, inspection and adjustment
Installing the fuel pump
23 - FUEL SYSTEM
25 - INLET & EXHAUST SYSTEM
Schematic
25 - INLET & EXHAUST SYSTEM
26 - COOLING SYSTEM
Changing the V-belt
Cooling system, description, from serial nr. EC 35 #283.18963, EC #45 284 17 799
Cooling system, disassembly_assembly, from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Cooling system, maintenance, from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Radiator, removal and installation from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Removing the coolant pump till serial nr. EC 35 #283 18 462, EC 45 #284 17 298
Removing the radiator
Removing the thermostat housing till serial nr. EC 35 #283 18 462, EC 45 #284 17 298
Schematic
Tensioning the V-belt
26 - COOLING SYSTEM
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
30 - GENERAL
Basic objects of examination
Colour codes
Complete wiring diagram (part 1) from serial nr. EC 35 #283 18 963; EC 45 # 284 17 799
Complete wiring diagram (part 2) from serial nr. EC 35 #283 18 963; EC 45 #284 17 799
Complete wiring diagram (part 2)
Designations of electrical components from serial nr. EC 35 #283 18 963; EC 45 #284 17 799
Diagnostics
Electrical system, description
Electrical system, technical data from serial nr. EC 35 # 283 18 963; EC 45 # 284 17 799
Electrical system, technical data
Electric system, trouble shooting
Identification of lines
Identification of plug connectors_lines_{08-31-15}
Identification of plug connectors_lines_{08-31-27}
Line connections in the wiring loom
Marking of plug connectors
Minus connection
Plus connection
Precautions when handling plug connectors
Wiring diagram - legend
30 - GENERAL
31 - BATTERY
Battery, description
Battery, specification
31 - BATTERY
32 - ALTERNATOR; CHARGE REGULATOR
Assemble the generator
Checking the performance characteristics
Checking the voltage regulation
Disassemble the generator
Generator
Installing the generator
Removing the generator
Tests before disassembly
32 - ALTERNATOR; CHARGE REGULATOR
33 - STARTING SYSTEM
Assembling the starter
Characteristics of the glow plug system
Checking the glow plug
Dismantling the starter
Installation of the solenoid
Installing the glow plug
Key-operated engine shut down system with EDD-solenoid
Removing the starter
Starter, preheating relay, ignition switch
Starter relay
Starting process
Start switch, specifications
Testing method
33 - STARTING SYSTEM
35 - LIGHTING
Boom_cabin_weather roof
Working headlights and main headlights, description
Working headlights and main headlights, specification
35 - LIGHTING
36 - OTHER ELECTRICAL EQUIPMENT
Operating_control elements on driver’s platform
Warning system
36 - OTHER ELECTRICAL EQUIPMENT
37 - CABLE; FUSE; RELAY
Fuses for cabin equipment
Fuses for machine equipment
Inside of machine_cabin light_cabin illumination_weather roof; fan_cabin heater - variant 1
Inside of machine_cabin light_cabin illumination_weather roof; fan_cabin heater - variant 2
Relay group_plug connector cabin_plug connector cabin heater fan
Relay
Solenoid valve, attachment carrier
Wiring cabin - console left
Wiring cabin - console right
Wiring engine - part 1
Wiring engine - part 2
Wiring engine - part 3
37 - CABLE; FUSE; RELAY
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
Electrical components (hydraulic system side)
Electrical components (machine side)
Electronic multi-function switch PUMA (ECU1)
error codes
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
4 - POWER TRANSMISSION
40 - GENERAL
General notes to be observe when working on power transmission assemblies
Working principle of the travel system
40 - GENERAL
44 - HYDROSTATIC DRIVE
Assembling pistons and guide sleeves
Assembling the cylinder block
Assembling the hydraulic motor
Assembling the oil distributor seals
Assembling the radial seals
Assembling the roller bearings
Assembling the travel gear
Brake valve (counter balance valve)
Design of axial piston motor
Design of travel motor
Design
Disassembling pistons and guide sleeves
Disassembling the hydraulic motor
Disassembling the roller bearings
Disassembling the travel motor
Fuels, lubricants and filling capacities (litres)
Function
High speed solenoid valve
Hydraulic motor 1, travel gear
Hydraulic motor 1 – travel system
Hydraulic motor – slewing of superstructure
Hydraulic motor, slewing
Installing the travel motor
Mechanical transmission - track gearbox
Plugs with tapered thread
Removing the cylinder block
Removing the gear motor
Removing the oil distributor seals
Removing the radial seals
Specifications
Strength class 10.9 Metric coarse and fine threads
Strength class 8.8 Metric coarse and fine threads
Technical data
Travel gear
UNC-threads, coarse pitch
44 - HYDROSTATIC DRIVE
49 - MISCELLANEOUS
Applying the brake
Assembling the brake discs
Miscellaneous
Releasing the slewing brake
Removing the brake discs
49 - MISCELLANEOUS
5 - BRAKE
53 - TRACK BRAKE
Brake, description
53 - TRACK BRAKE
6 - STEERING
60 - GENERAL
Steering system, description
60 - GENERAL
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
71 - FRAME
Assembling the superstructure
Frame, technical data
General description
Removing the superstructure
Slewing ring, tightening torques
71 - FRAME
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
Adjusting the track sagging
Assembling the crawler track
Assembling the guide sprocket
Assembling the rubber track
Drive gear, tightening torque
Drive sprocket
Removing the crawler tracks
Removing the guide sprocket
Removing the rubber track
Removing the track roller
Removing the track supporting idler
Sprocket, wear measurement
Track pad, tightening torque
Track roller, tightening torque
Track supporting idler, tightening torque
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
80 - GENERAL
Assembling the cabin
Cabin door, description
Cabin, specification
Cabin, tightening torques
Removing the cabin
Windscreen
80 - GENERAL
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS
81 - CAB, NAKED; CANOPY
90 - GENERAL
Hydraulic components, cleanliness during handling
Hydraulic components, storing and transporting
Hydraulic oil, description
Hydraulic oil, storage and handling
Hydraulic system, capacities
Hydraulic system, description
90 - GENERAL
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
Assembling the valve block
Auxiliary block with stand-by valve
Auxiliary pressure block
Balancing valve (offset cylinder)
Balancing valve (offset cylinder) Test and adjustment procedure
Changing the hydraulic oil filter
Checking and adjusting the breaker (volumetric capacity)
Checking and adjusting the dipper arm cylinder (volumetric capacity)
Checking and adjusting the FR pressure control valve
Checking and adjusting the LS pressure relief valve
Checking and adjusting the pilot pressure
Checking the hydraulic oil level
Control valve block for slewing gear, test and adjustment
Control valve
Dismantling the valve block
General
Hose rupture valve on boom cylinder, leak test
Hose rupture valve on boom cylinder
Hose rupture valve on boom cylinder Test and adjustment procedure
Hose rupture valve on dipper arm cylinder, leakage test
Hose rupture valve on dipper
Hydraulic lock, hose rupture valve
Hydraulic oil tank, filling capacity
Hydraulic safety solenoid valve
Installing the hydraulic pump from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Installing the hydraulic pump
Installing the valve block, from serial nr. EC 35 # 283 18 963; EC 45 # 284 17 799
Installing the valve block
Oil cooler, removal and installation, from serial nr. EC 35 #283 18 963; EC 45 #284 17 799
Oil cooler, removal and installation
Oil cooling system, cleaning, from serial nr. EC 35 #283 18 963; EC 45 #284 17 799
Oil cooling system, cleaning
Power control pressure limiting valve (relief valves)
Pressure regulator (hydraulic control elements)
Pressure relief valves
Removing the hydraulic oil pump from serial nr. EC 35 #283 18 963, EC 45 #284 17 799
Removing the hydraulic oil pump
Removing the valve block, from serial nr. EC 35 # 283 18 963; EC 45 # 284 17 799
Removing the valve block
Solenoid valve for hydraulic working unit
Stand-by pressure
Test and adjustment values EC 35
Test and adjustment values EC 45 from serial nr.: # 284 17 799
Test and adjustment values EC 45
Test and adjustment values EC 45
Valve block for slewing gear
Way valve, control valve
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
99 - MISCELLANEOUS
Hydraulic circuit, boom
Hydraulic circuit, dipper arm
Hydraulic circuit, dozer blade
Hydraulic circuit for bucket
Hydraulic circuit, slewing gear_offset
Hydraulic circuit, travel system
Hydraulic diagram, complete from serial nr. EC 35 # 283 18 963
Hydraulic diagram, complete from serial nr. EC 45 #284 17 799
Hydraulic diagram EC 35, complete
Hydraulic diagram EC 45, complete
Hydraulic system, auxiliary pressure block from serial nr. EC 35 #283 18 963; EC 45 #284 17 799
Hydraulic system, auxiliary pressure block
Hydraulic system, function diagram from serial nr. EC 35 #283 18 963; EC 45 # 284 17 799
Hydraulic system, function diagram
Return flow, hydraulic circuit for accessories from serial nr. EC 35 # 283 18 963; EC 45 # 284 17 799
Return flow, hydraulic circuit for accessories
Servo hydraulics from serial nr. EC 35 # 283 18 963; EC 45 # 284 17 799
Servo hydraulics
99 - MISCELLANEOUS
Volvo EC35 Compact Excavators Service Repair Manual
