Volvo L35G Compact Wheel Loaders Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo L35G Compact Wheel Loaders, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Volvo Constructions L35G Compact Wheel Loaders 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.
Volvo L35G Compact Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,412 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
03 - SPECIFICATIONS................4
Measurement conversion tables................5
Volvo standard tightening torques................10
07 - STANDARD TIME................12
Operation numbers for additional work................13
08 - TOOL................15
E-tool Cab support................16
Infrared Thermometer................17
1 - STANDARD PARTS; SERVICE................21
16 - LUBRICANT; FUEL; OTHER FLUID................22
Recommended lubricants_{08-51-10}................23
Recommended lubricants_{08-50-37}................26
Coolant with freezing and corrosion protection................29
Fuel; recommendation................30
This statement is only valid for Volvo branded engines._{08-46-53}................31
Engine oil................34
17 - SERVICE................35
Service................37
Service and maintenance................38
Work on the machine's electrical system................40
Cleanliness; braking and hydraulic system................41
Charging batteries................42
Electric welding................43
Tech Tool; operations ................44
Service position 2_{08-41-43}................45
Service position 1_{08-41-15}................48
Maintenance service; every 10 hours................51
Maintenance service; every 50 hours................52
Maintenance service; every 500 hours................53
Maintenance service; every 1000 hours................54
Maintenance service; every 1500 hours................56
Maintenance service; every 2000 hours................58
Maintenance service; every 3000 hours................60
Maintenance service; every 6000 hours................62
Test running and checking................63
Leakage; checking................64
Lubrication................65
Engine belt tension; checking................67
Crankcase ventilation separator element; replacing................70
Valves; adjusting ................72
Engine oil level; checking................76
Engine oil and filter; changing................77
Water separator; checking................79
Fuel filters; replacing................80
Fuel tank breather filter; replacing................82
Fuel injectors; checking................83
Diesel particulate filter; checking and cleaning................84
Turbocharger; checking................91
Engine air cleaner primary filter; replacing................92
Engine air cleaner secondary filter; replacing................94
Coolant level; checking................95
Coolant; changing................97
Coolant freezing point; checking................100
Radiator and hydraulic oil cooler; cleaning................102
EGR system; checking................103
MATRIS and Tech Tool; reading................112
Battery; checking................113
Axle oil; changing................114
Brake fluid level; checking................117
Service brake pads; checking................118
Steering pressure; checking ................119
Steering cylinders; locking of pivot pins; checking................122
Tyre wear and air pressure; checking................123
Wheel nuts torque; checking................124
Cab main filter; replacing................125
Hydraulic oil level; checking................127
Hydraulic oil; changing................129
Hydraulic oil filters; replacing................131
Hydraulic tank sediment; draining................133
Hydraulic pressure; checking................134
Towing a disabled machine................137
19 - GENERAL................139
Safety concerns everybody!................140
CE-marking; EMC-directive................142
Safety when handling the machine................146
Safety rules when servicing................150
Service position 2................153
Service position 1................156
Loader boom; safety strut................159
Working under raised boom................162
Fire prevention measures................164
Some simple rules regarding tyre handling................167
Safety when lifting and supporting complete machine................169
Safety when working with batteries................171
Starting with booster batteries................174
Safety when handling oils and fuel................176
Safety when handling accumulators................177
Safety when working on hydraulic systems................178
Checklist after a fire or heat exposure................180
Health hazards with paint; plastics and rubber................181
Environmental handling for the future................183
Waste handling................185
Environmentally safe handling................186
Environmentally hazardous fluids................188
Safety when working with refrigerant................189
Working in environmentally contaminated areas................192
Decontamination................193
2 - ENGINE WITH MOUNTING AND EQUIPMENT................195
20 - GENERAL................196
Engine; description_{05-11-15}................197
Engine; description_{05-11-13}................201
Engine; description_{05-10-43}................204
E-ECU MID 128 pre-programmed; replacing................208
E-ECU MID 128 non-programmed; replacing................210
Tech Tool; operations-[5104]................212
Component locations_{04-50-35}................214
Engine; capacity_{04-08-26}................217
Engine; capacity_{04-08-05}................218
Engine; weights_{04-07-13}................219
Engine; weights_{04-06-51}................220
Electric components location_{01-52-07}................221
Electric components location_{01-51-43}................224
21 - ENGINE................227
Engine; specifications_{01-49-23}................228
Engine; specifications_{01-49-02}................229
Engine; removing................231
Engine; installing................239
Cylinder compression; testing................246
Cylinder head gasket; replacing................248
Valve system specifications................265
Valves; adjusting................266
Valve cover; removing................270
Valve cover; installing................273
22 - LUBRICATING SYSTEM................276
Lubricating system; description_{10-27-08}................277
Lubricating system; description_{10-26-43}................281
Lubrication system; specifications................285
Lubrication system; tightening torques................286
Oil pressure relief valve; replacing................287
Lubrication oil pressure; checking................289
Oil cooler; replacing................291
23 - FUEL SYSTEM................293
Fuel system; description_{09-51-42}................294
Fuel system; description_{09-51-02}................299
Fuel system; specifications................305
Fuel tank; capacities................306
Fuel system; tightening torques................307
Fuel pump unit; replacing ................308
Fuel tank; replacing................317
Fuel tank level sensor; replacing................320
Injectors; tightening torques................322
Injectors; replacing................323
Fuel pump unit; replacing................326
25 - INLET & EXHAUST SYSTEM................335
Inlet and exhaust system; description................336
Inlet and exhaust system; component location................340
Exhaust Aftertreatment System; description_{09-41-07}................342
Exhaust Aftertreatment System; description_{09-40-37}................346
Exhaust Aftertreatment System; description_{09-40-04}................350
Exhaust Aftertreatment System; component location_{10-36-12}................354
Exhaust Aftertreatment System; component location_{10-35-48}................356
Regeneration process; description................358
DPF (Diesel particulate filter); checking and cleaning................360
Inlet throttle; replacing................367
Charge air cooler; replacing................371
26 - COOLING SYSTEM................374
Cooling system; description................375
Cooling system; capacity................378
Cooling package; removing................379
Cooling package; installing................390
Coolant pump; replacing................399
Thermostat; replacing................401
Cooling fan rpm; specifications................403
Cooling fan; description_{10-26-32}................405
Maximum fan speed; checking................407
Fan motor; removing_{10-24-50}................411
Fan motor; removing_{10-24-20}................418
Fan motor; installing_{07-40-10}................424
Fan motor; installing_{07-39-44}................430
29 - MISCELLANEOUS................436
Exhaust Gas Recirculation (EGR); description_{07-38-58}................437
Exhaust Gas Recirculation (EGR); description_{07-38-24}................441
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................445
30 - GENERAL................446
Electrical system; work instructions................450
Electrical system; description................453
Electronic control system; description................455
Communication with data buses................458
Electrical system; specifications................460
Tech Tool; operations ................461
Automatic engine shut down; description................463
Software parameters; description................465
Power derating_{07-32-41}................472
Power derating_{07-32-19}................474
DPF regeneration control_{07-31-40}................475
DPF regeneration control_{07-31-15}................482
General fault diagnosis information................486
Troubleshooting strategy................488
Collection of basic data................490
Error codes; build-up................492
SAE error codes; translation to error messages; general................495
Conditions when checking................497
Lead and connector checks................500
Troubleshooting tools................504
Special tools for troubleshooting................505
Tech Tool; operations................506
AL3201; description and measuring................507
FX1005; description and measuring_{07-22-20}................509
FX1005; description and measuring_{07-21-42}................511
FX1052; description and measuring................513
FX1053; description and measuring................516
FX1054; description and measuring................518
MA2301-MA2304; description and measuring................520
MA2310; description and measuring................522
MA2602; description and measuring_{07-13-57}................524
MA2602; description and measuring_{07-13-07}................526
MA4220; description and measuring_{07-12-07}................528
MA4220; description and measuring_{07-11-17}................530
MA4221; description and measuring_{07-10-18}................532
MA4221; description and measuring_{07-09-29}................534
MA4234; description and measuring................536
MA4235; description and measuring_{07-07-17}................538
MA4235; description and measuring_{07-06-37}................540
MA4605; description and measuring_{07-05-42}................542
MA4605; description and measuring_{07-04-59}................544
MA4710_MA4711; description and measuring_{07-04-06}................546
MA4710_MA4711; description and measuring_{07-03-26}................548
MA4720; description and measuring_{07-02-27}................550
MA4720; description and measuring_{07-01-36}................552
MA9172_MA9174; description and measuring_{07-00-37}................554
MA9173; description and measuring_{06-59-45}................556
PWM2602; description and measuring_{06-58-30}................558
PWM2602; description and measuring_{06-58-00}................560
RE01; description and measuring................562
RE04; description and measuring................564
RE05; description and measuring_{06-55-18}................566
RE05; description and measuring_{06-54-34}................568
RE2501; description and measuring_{06-53-28}................570
RE2501; description and measuring_{06-52-51}................572
RE3301; description and measuring................574
RE3504; description and measuring_{06-51-02}................576
RE3504; description and measuring_{06-50-18}................578
RE3505. description and measuring................580
RE8701; description and measuring................582
SAE J1939_CAN1 Control link; description and measuring_{06-46-33}................584
SAE J1939_CAN1 Control link; description and measuring_{06-46-00}................586
SAE J1939_CAN2 control link; description and measuring_{06-45-12}................588
SAE J1939_CAN2 control link; description and measuring_{06-44-31}................591
SE2206; description and measuring................594
SE2303; description and measuring_{06-42-26}................596
SE2303; description and measuring_{06-41-47}................599
SE2306; description and measuring................601
SE2309; description and measuring................603
SE2502; description and measuring_{06-39-00}................605
SE2502; description and measuring_{06-38-28}................607
SE2507; description and measuring................609
SE2508; description and measuring................611
SE2510; description and measuring_{06-35-59}................613
SE2510; description and measuring_{06-35-24}................615
SE2519; description and measuring_{06-34-36}................617
SE2519; description and measuring_{06-34-07}................619
SE2521; description and measuring_{06-33-25}................621
SE2521; description and measuring_{06-32-50}................623
SE2522; description and measuring_{06-31-56}................625
SE2522; description and measuring_{06-31-20}................627
SE2606; description and measuring................629
SE2702; description and measuring_{06-29-33}................631
SE2702; description and measuring_{06-28-53}................633
SE2709; description and measuring................635
SE2710; description and measuring................637
SE4307; description and measuring................639
SE9105; description and measuring................641
SE9106; description and measuring................643
SW2506; description and measuring_{06-22-36}................645
SW2506; description and measuring_{06-22-11}................647
SW4205; description and measuring................649
Component descriptions................651
Limp Home................654
31 - BATTERY................656
Battery; description................657
Battery; specifications................658
Battery; charging................659
32 - ALTERNATOR; CHARGE REGULATOR................660
Alternator; replacing incl function checking................661
Alternator; testing................663
33 - STARTING SYSTEM................665
Booting sequence................666
Preheating; specifications................667
Glow plug; removing................668
Glow plug; installing................670
Glow plugs; testing................672
36 - OTHER ELECTRICAL EQUIPMENT................673
Windscreen wiper front motor; replacing................674
Connectors; overview................678
37 - CABLE; FUSE; RELAY................682
Wiring diagram; electrical distribution box - Image................686
Electrical symbols and designations................687
Cable and component designations_{006-06-28}................691
Cable and component designations_{006-06-07}................693
Cable and component marking explanations................695
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{006-04-58}................697
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{006-04-37}................699
Component list Fuses_{006-04-04}................701
Component list Fuses_{006-03-39}................704
Component list Heating coils; instruments; service socket_{006-03-04}................707
Component list Heating coils; instruments; service socket_{006-02-43}................708
Component list Lights_{006-02-11}................709
Component list Lights_{006-01-50}................711
Component list; motors_{006-01-11}................713
Component list; motors_{006-00-50}................714
Component list; PWM valves_{006-00-17}................715
Component list; PWM valves_{005-59-56}................716
Component list Relays_{005-59-23}................717
Component list Relays_{005-58-59}................720
Component list; sensors_{005-58-11}................723
Component list; sensors_{005-57-50}................725
Component list Solenoid valves_{005-57-17}................727
Component list Solenoid valves_{005-56-56}................729
Component list; Sounders_{005-56-23}................731
Component list; Sounders_{005-56-02}................732
Component list Switches_{005-55-23}................733
Component list Switches_{005-55-02}................735
Connector I_O description_{005-54-29}................737
Connector I_O description_{005-54-04}................756
Table of contents; wiring diagrams_{005-53-27}................769
Table of contents; wiring diagrams_{005-53-05}................771
Wiring diagram; electrical distribution box................773
Wiring diagram WD201_{05-52-03}................776
Wiring diagram WD201_{05-51-38}................780
Wiring diagram WD202_{05-51-02}................784
Wiring diagram WD202_{05-50-38}................788
Wiring diagram WD203_{05-50-02}................791
Wiring diagram WD203_{05-49-38}................795
Wiring diagram WD204................798
Wiring diagram WD205................801
Wiring diagram WD301_{05-48-02}................804
Wiring diagram WD301_{05-47-37}................808
Wiring diagram WD302_{05-47-02}................811
Wiring diagram WD302_{05-46-37}................815
Wiring diagram WD303_{05-46-02}................818
Wiring diagram WD303_{05-45-37}................821
Wiring diagram WD304_{05-45-02}................824
Wiring diagram WD304_{05-44-38}................828
Wiring diagram WD305_{05-43-56}................831
Wiring diagram WD305_{05-43-32}................835
Wiring diagram WD306_{05-42-56}................839
Wiring diagram WD306_{05-42-32}................843
Wiring diagram WD307_{05-41-56}................846
Wiring diagram WD307_{05-41-32}................849
Wiring diagram WD308_{05-40-44}................853
Wiring diagram WD308_{05-40-20}................857
Wiring diagram WD309_{05-39-44}................860
Wiring diagram WD309_{05-39-21}................863
Wiring diagram WD310_{05-38-45}................866
Wiring diagram WD310_{05-38-21}................870
Wiring diagram WD311_{05-37-45}................873
Wiring diagram WD311_{05-37-21}................876
Wiring diagram WD312_{05-36-45}................880
Wiring diagram WD312_{05-36-21}................883
Wiring diagram WD313_{05-35-46}................885
Wiring diagram WD313_{05-35-22}................888
Wiring diagram WD314_{05-34-47}................891
Wiring diagram WD314_{05-34-23}................894
Wiring diagram WD315_{05-33-47}................897
Wiring diagram WD315_{05-33-23}................900
Wiring diagram WD316................902
Wiring diagram WD317................905
Wiring diagram WD401_{05-31-47}................908
Wiring diagram WD401_{05-31-23}................912
Wiring diagram WD402................915
Wiring diagram WD501_{05-30-17}................919
Wiring diagram WD501_{05-29-53}................922
Wiring diagram WD801_{05-29-17}................925
Wiring diagram WD801_{05-28-53}................928
Wiring diagram WD802_{05-28-17}................931
Wiring diagram WD802_{05-27-53}................935
Wiring diagram WD803................939
Wiring diagram WD804................942
Wiring diagram WD901_{05-26-06}................945
Wiring diagram WD901_{05-25-41}................949
Wiring diagram WD902_{05-25-05}................954
Wiring diagram WD902_{05-24-42}................957
Wiring diagram WD903_{05-24-06}................960
Wiring diagram WD903_{05-23-42}................963
Wiring diagram WD904_{05-23-06}................966
Wiring diagram WD904_{05-22-42}................970
Wiring diagram WD905................973
Wiring diagram WD906................976
Component location 001................979
Component location 002................981
Component location 003................984
Component location 004................987
Component location 005................989
Component location 006................991
Component location 007................993
Component location 008................995
Component location 009................997
Component location 010................999
Component location 011................1001
Component location 012................1003
Component location 013................1005
Component location 014................1008
Component location 015................1010
Component location 016................1012
Component location 017................1014
Component location 018................1017
Component location 019................1019
Grounding points; frame connections_{005-10-55}................1022
Grounding points; frame connections_{005-10-31}................1024
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM................1026
Information display; general................1027
Information display; start lockout................1029
Service mode; description................1031
CareTrack W-ECU; description................1035
4 - POWER TRANSMISSION................1039
40 - GENERAL................1040
Power transmission; description................1041
42 - TRANSMISSION; HYDRAULIC CONTROL................1042
Induction sensor for output shaft; replacing................1043
44 - HYDROSTATIC DRIVE................1045
Power transmission; specifications................1046
Travel motor; description................1047
Hydrostatic pump; description................1050
Hydraulic motor; replacing................1053
Hydraulic pump coupling; description................1055
Shaft seal replacing................1057
Hydrostatic pump charge pressure; checking and adjusting................1060
Start hydraulic pump control; checking and adjusting................1062
Hydrostatic pump high pressure valve; checking and adjusting................1065
Hydrostatic pump cut off valve; checking and adjusting................1068
Hydrostatic pump mechanical zero position; checking and adjusting................1071
46 - FRONT AXLE; REAR AXLE................1074
Drive axles; description................1075
Front axle; specification................1077
Front axle; weight................1078
Front axle; capacity................1079
Rear axle; specification................1080
Rear axle; weight................1081
Rear axle; capacity................1082
Axles and propeller shaft; tightening torque................1083
Front axle; removing................1084
Front axle; installing................1087
Axle; removing................1089
Axle; installing................1095
49 - MISCELLANEOUS................1101
Hydraulic diagram transmission - Image................1102
Hydraulic diagram transmission_{04-48-45}................1104
Hydraulic diagram transmission_{04-48-21}................1107
5 - BRAKE................1110
50 - GENERAL................1111
Description brake system_{04-46-47}................1112
Description brake system_{04-46-23}................1114
Brakes; specifications_{04-45-48}................1115
Brakes; specifications_{04-45-27}................1116
Brake design_{04-44-54}................1117
Brake design_{04-44-30}................1119
51 - WHEEL BRAKE................1122
Brake disc; replacing one................1123
Brake pads; replacing................1126
52 - HYDRAULIC BRAKE SYSTEM................1129
Brake system; bleeding_{04-40-07}................1130
Brake system; bleeding_{04-39-46}................1132
Inching and brake pedal; adjusting_{04-39-13}................1134
Inching and brake pedal; adjusting_{04-38-52}................1137
6 - STEERING................1139
60 - GENERAL................1140
Steering system; description................1141
Steering unit; specification................1142
64 - STEERING................1143
Hydraulic diagram; steering - Image................1144
Troubleshooting and actions to fix problems................1146
Steering valve; hydraulic diagram_{04-35-57}................1148
Steering valve; hydraulic diagram_{04-35-33}................1150
Steering wheel; tightening torques................1152
Hydraulic diagram; steering_{04-33-25}................1154
Hydraulic diagram; steering_{04-33-04}................1156
Steering pressure; checking................1158
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT................1161
70 - GENERAL................1162
Frame and track unit; description................1163
Frame; weight................1165
71 - FRAME................1166
Counterweight; removing................1167
Counterweight; installing................1170
74 - FRAME LINK................1172
Frame joint; separating machine................1173
Frame joint; assembly of separated machine................1179
Frame joint; replacing bearings................1185
77 - WHEELS; TRACKS; TYRE; HUB; DRUM................1190
Wheel; tightening torque................1191
Tire size................1192
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE................1194
80 - GENERAL................1195
Cab description................1196
81 - CAB; NAKED; CANOPY................1197
Cab; removing................1198
Cab; installing................1209
Cab mounts; tightening torques................1219
82 - ENGINE HOOD; MUDGUARD; FOOT STEP................1220
Engine hood; installing_{04-21-11}................1221
Engine hood; removing_{04-22-18}................1223
Engine hood; removing_{04-21-52}................1226
Engine hood; installing_{04-21-19}................1229
84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING................1231
Windows; general................1232
Door window; replacing_{04-20-04}................1234
Rear window; replacing_{04-19-40}................1238
Windscreen; replacing_{04-19-16}................1247
87 - AIR CONDITIONING UNIT................1256
Electrical schematic - Image................1257
Heating system; description_{04-17-39}................1258
Heating system; description_{04-17-15}................1261
Air conditioning; capacity_{04-16-40}................1264
Air conditioning; capacity_{04-16-20}................1265
Air conditioning unit; maintenance................1266
Diesel heater; description................1268
Diesel heater; principles................1271
Diesel heater; specifications................1272
Symptom_malfunction................1274
Fault mode diagnosis................1276
Error code; troubleshooting................1278
Combination sensor; check................1281
Disassembly and assembly................1283
Electrical schematic................1288
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS................1291
90 - GENERAL................1292
Hydraulic diagram with option components - Image................1293
Flow control for 3rd hydraulic function - Image................1295
Hydraulic diagram; auxiliary pump Working hydraulics - Image................1297
3rd hydraulic function - Image................1298
Tilt speed limiter -Image................1299
Line rupture valve - Image................1300
Hydraulic diagram; working hydraulic system - Image................1301
Hydraulic function; 4th switchable from 3rd - Image................1302
Hydraulic diagram; Boom Suspension System - Image................1303
Hydraulic diagram; control valve - Image................1304
Cleanliness when working on hydraulic components................1305
Flow control for 3rd hydraulic function_{04-09-58}................1306
3rd hydraulic function_{04-09-34}................1310
Tilt speed limiter_{04-09-10}................1314
Line rupture valve_{04-08-46}................1317
Hydraulic diagram; working hydraulic system................1320
Hydraulic function; 4th switchable from 3rd................1323
Hydraulic diagram; cooling fan standard_{04-07-01}................1326
Hydraulic diagram; cooling fan standard_{04-06-40}................1328
Hydraulic diagram; cooling fan standard_{04-06-19}................1330
Hydraulic diagram; Boom Suspension System................1332
Hydraulic diagram; control valve................1334
General information to note when working on the hydraulic system................1336
Hydraulic oil; storage and handling................1338
Hydraulic system; repair of hydraulic components in workshop................1339
Hydraulic components; storing and transporting................1341
Troubleshooting chart................1342
Vacuum pump; connection................1345
91 - WORKING HYDRAULIC; SERVO HYDRAULICS................1348
Hydraulic system; description................1349
Hydraulic system; specification_{04-02-22}................1350
Hydraulic system; specification_{04-02-01}................1351
Hydraulic system; volume................1352
Hydraulic oil cooler; replacing................1353
Main control valve; description................1355
Main control valve; removing................1357
Main control valve; installing................1361
Port relief valve pressure; checking and adjusting_{03-59-19}................1364
Port relief valve pressure; checking and adjusting_{03-58-55}................1369
Hydraulic pumps; description................1374
Hydraulic pump; max working pressure; checking and adjusting................1375
Hydraulic pump; replacing................1378
Servo valve; description................1381
Servo valve; replacing................1385
Boom Suspension System; general description................1391
92 - MECHANICAL EQUIPMENT_ATTACHMENT................1394
Trailer hitch; specifications................1395
Trailer hitch................1397
Implemental attachment hydraulic cylinder; replacing................1400
94 - UNIT; LOAD HANDLING................1404
Lift cylinder; replacing................1405
Tilt cylinder; replacing................1408
Hydraulic cylinder creeping; checking................1411
Volvo L35G Compact Wheel Loaders Repair Service Manual
