Volvo Skid Steer Loaders MC135D Repair Service Manual

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Model: 
Price: US$ 49.00

Complete service repair manual with Electrical Wiring Diagrams for Volvo Skid Steer Loaders MC135D, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Volvo Constructions Skid Steer Loaders MC135D 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 Skid Steer Loaders MC135D Repair Service Manual.pdf

PRODUCT DETAILS:
Total Pages: 998 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
0 - GENERAL...2
  03 - SPECIFICATIONS...3
    Tightening torque; specifications...4
    Conversion tables...9
    Thread locking compound; application_specifications...17
    Quick release couplings...19
    Hydraulic connections; tightening torques...23
    Push lock fittings...30
  07 - STANDARD TIME...32
    Operation numbers for additional work...33
1 - STANDARD PARTS; SERVICE...35
  16 - LUBRICANT; FUEL; OTHER FLUID...36
    Fuel; lubricant and filling capacities...37
  17 - SERVICE...39
    Arrival Inspection; according to Inspection Programme...41
    Delivery Inspection; according to Inspection Programme...42
    Maintenance of Stored Machines; according to Inspection Programme...43
    Maintenance service; every 10 hours...44
    Maintenance service; every 50 hours...45
    Maintenance service; every 500 hours...47
    Maintenance service; every 1000 hours...49
    Maintenance service; every 1500 hours...51
    Maintenance service; every 2000 hours...53
    Maintenance service; every 3000 hours...55
    Lubrication; every 10 hours...57
    Leakage; checking...59
    Engine belt condition; checking...60
    Engine belt; replacing_46-58...62
    Crankcase ventilation separator element; replacing...64
    Engine oil level; checking...66
    Engine oil and filter; changing...68
    Water separator; checking...71
    Fuel filter; replacing...73
    Water separator filter; replacing...74
    Exhaust system integrity; checking...76
    Spark arrester; cleaning...77
    Engine air cleaner system integrity; checking...79
    Engine air cleaner primary filter; replacing...80
    Engine air cleaner secondary filter; replacing...82
    Coolant level; checking...84
    Coolant; changing...86
    Cooling system integrity; checking...88
    Coolers; cleaning...90
    Battery terminals; cleaning...91
    Battery isolator switch; checking...92
    Alternator; checking...93
    Starter motor; checking...97
    Wiring harness integrity; checking...101
    Drive chain oil level; checking...102
    Drive chain case oil; changing...104
    Tyre wear and air pressure; checking...106
    Wheel nuts torque; checking...108
    Track tension and condition; checking...109
    Track sprocket bolt torque; checking...111
    Cab heating and air conditioning filter; replacing...113
    Hydraulic oil level; checking...115
    Hydraulic oil; changing...116
    Hydraulic oil filters; replacing...118
    Hydraulic oil tank breather filter; replacing...121
    Cylinder rams condition; checking...123
  19 - GENERAL...124
    Safety concerns everybody!...125
    Service position...129
    Some simple rules regarding tyre handling...139
    Safety when handling the machine...141
    Before operating...145
    Before service; read...149
    General...153
    Cleanliness...158
    Electrical system...162
    Checklist after a fire or heat exposure...166
    Health hazards with paint; plastics and rubber...169
    Safety when handling oil and fuel...173
    Safety when working with batteries...175
    Environment...178
    Environmental handling for the future...183
    Decontamination...185
2 - ENGINE WITH MOUNTING AND EQUIPMENT...189
  20 - GENERAL...190
    Engine belt; replacing...191
  21 - ENGINE...193
    Engine; removing...195
    Engine; installing...199
    Engine rotation speed sensor (camshaft); replacing...200
    Engine rotation speed sensor (crank shaft); replacing...202
    Cylinder compression; testing...205
    Engine; specifications...206
    Crankcase; specifications...208
    Engine timing gears; description...210
    Engine; description...213
    Engine; component locations...221
    Rocker levers; rocker shaft and tappets; specifications...228
    Camshaft; specifications...230
    Camshaft position sensor; description...231
    Pistons; specifications...233
    Fault tracing; engine...235
    Crankshaft position sensor; description...249
    Cylinder head; replacing...251
    Engine bedplate; replacing...254
    Pistons; description...260
    Connecting rod; specifications...263
    Big end bearing; replacing...264
    Big end bearing; checking...268
    Piston; replacing...269
    Piston; disassembling and assembling...272
    Valves; adjusting...275
    Valves; replacing...280
    Rocker assembly; replacing...284
    Cylinder head valves; specifications...287
    Rocker assembly; disassembling and assembling...289
    Rocker cover; replacing...292
    Rocker assembly; checking...295
    Rocker assembly; description...296
    Camshaft; replacing...299
    Camshaft; checking...303
    Crankshaft; specifications...304
    Crankshaft front oil seal; replacing...305
    Crankshaft rear oil seal; replacing...308
    Crankshaft main bearing; replacing...313
    Crankshaft main bearing; checking...317
    Flywheel; replacing...319
    Flywheel housing; replacing...321
    Flywheel gear ring; replacing...324
    Flywheel drive plate; replacing...326
    Rear timing case; replacing...328
    Crankshaft gear; replacing...332
    Heavy duty PTO gear; replacing...335
    Tappet cover; replacing...338
    Crankshaft; replacing...340
    Crankshaft; checking...346
    Tappets; replacing...348
    Connecting rod; checking...352
    Crankshaft pulley; replacing...353
    Oil sump; description...356
    Oil sump; replacing...358
    Engine mounts; replacing...362
  22 - LUBRICATING SYSTEM...363
    Lubrication system; specifications...364
    Oil pump; description...365
    Oil pump; replacing...368
    Lubrication oil pressure; checking...371
    Oil cooler; replacing...374
    Oil cooler; disassembling and assembling...377
    Oil cooler; description...379
  23 - FUEL SYSTEM...381
    Fuel system; description...382
    Fuel injection pump; description...393
    Fuel; specifications...396
    Fault tracing; fuel system...399
    Fuel pump; specifications...407
    Fuel pipes; description...408
    Fuel pump; replacing...410
    Fuel system; bleeding...413
    Injection pump; replacing...414
    Fuel injection pump gear; replacing...421
    Injectors seal; replacing...423
    Fuel rail; replacing...426
    Low pressure fuel pipes; replacing...428
    Injectors; replacing...432
    Fuel rail pressure; checking...436
    High pressure fuel pipes; replacing...439
    Fuel injector; testing...444
  25 - INLET & EXHAUST SYSTEM...446
    Turbocharger; description...447
    Variable Geometry Turbocharger (VGT); description...449
    Inlet and exhaust system; specifications...454
    Exhaust manifold; replacing...456
    Inlet manifold; replacing...458
    Turbocharger; replacing...461
    Turbocharger; checking...464
    Variable geometry turbocharger (VGT); replacing...466
    Variable geometry turbocharger (VGT) actuator; replacing...469
  26 - COOLING SYSTEM...471
    Fan control valve; description...472
    Cooling system; specifications...475
    Coolant temperature sensor; description...476
    Cooling system; description...478
    Fault tracing; cooling system...480
    Expansion tank; replacing...483
    Cooling package; removing...485
    Cooling package; installing...488
    Thermostat; checking...491
    Coolant pump; replacing...493
    Thermostat; description...496
    Coolant pump; description...499
    Fan control valve; removing...501
    Fan control valve; installing...503
    Cooling fan solenoid; replacing...505
    Belt tensioner; replacing...507
  27 - ENGINE CONTROL...509
    Electronic throttle control; description...510
    Engine control unit (E-ECU); description...512
    Accelerator pedal; replacing...515
    Cold start advance solenoid; replacing...518
  29 - MISCELLANEOUS...520
    EGR cooler; replacing...521
    Exhaust Gas Recirculation (EGR); description...526
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS...530
  30 - GENERAL...531
    Electrical system; specifications...532
    Fault code list...533
    Collection of basic data...538
    Lead and connector checks...541
    Multimeter...546
    Logic control...548
  31 - BATTERY...555
    Battery maintenance...556
    Battery; description...558
    Battery; specification...559
    Battery; removing...560
    Battery; installing...562
  32 - ALTERNATOR; CHARGE REGULATOR...564
    Alternator; specifications...565
    Alternator; description...566
    Alternator removing; inspecting and installing...568
    Alternator; disassembling and assembling...573
  33 - STARTING SYSTEM...576
    Starter motor; description...577
    Starter motor removing; inspecting and installing...578
    Starter motor; disassembling and assembling...582
  35 - LIGHTING...585
    Work lights; description...586
    Work lights; replacing_{20-48}...589
    Work lights; replacing_{20-28}...591
    Road lights; description...593
    Direction indicator; replacing...595
  36 - OTHER ELECTRICAL EQUIPMENT...597
    Radio; specifications...598
    Back up alarm; replacing...602
    White noise_reverse alarm; description...604
    Windscreen wiper tank fluid; changing...605
    Windscreen wiper tank; replacing...606
    Windscreen wiper system; description...608
    Windscreen wiper front motor; replacing...612
    Windscreen wiper; replacing...615
    Hand throttle control switch; description...618
  37 - CABLE; FUSE; RELAY...620
    Explanation of wiring diagrams...621
    Wiring diagram 1...622
    Wiring diagram 2...624
    Wiring diagram 3...625
    Wiring diagram 4...626
    Wiring diagram 5...627
    Wiring diagram 6...628
    Wiring diagram 7...629
    Wiring diagram 8...630
    Wiring diagram 9...631
    Wiring diagram 10...633
    Wiring diagram 11...635
    Battery isolator...637
    Battery disconnect switch; replacing...639
  38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM...641
    Engine oil pressure sensor; replacing...642
    Hourmeter; replacing...643
    Knock sensor; description...645
    Knock sensor; replacing...646
    Exhaust manifold temperature sensor; replacing...648
    Exhaust manifold pressure sensor; replacing...650
    Temperature and manifold air pressure (TMAP) sensor; replacing...652
    Temperature and mass airflow (TMAF) sensor; replacing...654
    Coolant temperature sensor; replacing...656
    Engine oil temperature sensor; replacing...658
    Intercooler outlet temperature sensor; replacing...660
    Engine oil pressure switch; replacing...662
4 - POWER TRANSMISSION...664
  42 - TRANSMISSION; HYDRAULIC CONTROL...665
    Transmission solenoids; description...666
    Transmission solenoid; replacing...668
    Transmission pilot solenoid; replacing...670
  44 - HYDROSTATIC DRIVE...672
    Driveline; description...673
    Drive motor; description_{01-19}...681
    Drive motor; description_{00-59}...687
    Tensioner_recoil unit; specifications...690
    Drive motor; removing_{59-28}...691
    Drive motor; removing_{59-10}...694
    Drive motor; installing...698
    Drive motor adapter; replacing...700
    Pump_engine coupling; description...702
    Transmission pump; Specifications...704
    Transmission pump; adjusting...706
    Transmission pump; disassembling and assembling...712
    Transmission pump; description...718
    Drive chain; description...721
    Pump coupling; installing...723
    Pump coupling; removing...725
    Transmission pump; specifications...727
    Transmission pump; removing...728
    Transmission pump; installing...730
    Transmission pump; restoring...732
    Drive chain; removing...734
    Drive chain; installing...737
  46 - FRONT AXLE; REAR AXLE...739
    Drive motor; disassembling and assembling...740
    Wheel hub; description...742
    Wheel hub condition; checking...743
    Wheel hub assembly; replacing...744
5 - BRAKE...747
  55 - PARKING BRAKE...748
    Parking brake; disassembling...749
    Parking brake; assembling...751
    Parking brake; description and operation...755
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT...758
  71 - FRAME...759
    Stop pad; adjusting...760
    Stop pad; removing...762
    Stop pad; installing...764
  77 - WHEELS; TRACKS; TYRE; HUB; DRUM...766
    Tyre; specifications...767
    Roadwheels; replacing...768
    Wheel; description...770
    Recoil unit; disassembling and assembling...771
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE...773
  81 - CAB; NAKED; CANOPY...774
    Cab; removing...775
    Cab; installing...779
    Operator's station; introduction...782
    Operator's protective structure; description...785
  83 - DOORS; HATCH; COVER PLATE; (all)...787
    Cabin door; description...788
    Cab door; removing...790
    Cab door; installing...792
    Cab door hinge; removing...794
    Cab door hinge; installing...796
    Door handle; replacing...798
  84 - TRIM PART; OUTSIDE; GLASS; SEALING MOULDING...801
    Side mirror; removing...802
    Side mirror; installing...804
    Windows; description...806
    Window; preparing...808
    Window pane; removing...812
    Window pane; installing...816
  85 - CAB INTERIOR; UPHOLSTERY...823
    Seat; replacing...824
  86 - PROTECTIVE EQUIPMENT...826
    Door guard; replacing...827
  87 - AIR CONDITIONING UNIT...829
    Air conditioning; specifications...830
    Air conditioning unit; general...832
    Expansion valve; description...835
    Compressor; description...837
    Water valve; description...839
    Refrigerant pipe; description...841
    Water valve; replacing...842
    Air conditioning; component location...844
    Air conditioning; description...846
    Wiring diagram; HVAC...848
    Fault tracing; HVAC...851
    HVAC; discharging and pressurizing...853
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS...857
  90 - GENERAL...858
    Hydraulic diagram 1 - Image...859
    Explanations to hydraulic diagram...861
    Hydraulic diagram 1_{10-14}...866
    Hydraulic diagram 1_{09-37}...868
    Joystick control; replacing...870
    Hydraulic system; description...872
    Hydraulic system; bleeding...874
    Fault tracing on hydraulic system...876
    Boom suspension system (BSS) valve block; specifications...878
    Boom suspension system accumulator (BSS); specifications...879
    Charge pump; specifications...881
    Hydraulic service procedures...882
    Hydraulic system; flushing...885
  91 - WORKING HYDRAULIC; SERVO HYDRAULICS...887
    Hydraulic oil temperature sensor; description...889
    Hydraulic tank; description...890
    Hydraulic return line filter; specification...892
    Hydraulic tank; specifications...893
    Hydraulic cylinders; specifications...894
    Hydraulic oil tank; replacing...895
    Auxiliary hydraulic pressure; releasing...898
    Hydraulic pressure sensor; description...900
    Hydraulic cylinder; description...901
    Boom suspension system valve; description...904
    Hydraulic pressure sensor; replacing...906
    Boom suspension system valve; replacing...908
    Boom suspension system accumulator; charging and discharging...910
    Self level valve; description...913
    Self level valve; replacing...916
    Smooth ride system; description...917
    Smooth ride system solenoid; replacing...922
    Smooth ride system valve; replacing...924
    Self level valve; specifications...926
    Gear pump; specifications...927
    Gear pump; description...928
    Gear pump; replacing...930
    Gear pump; disassembling and assembling...933
    Fault tracing on hydraulic system_{50-21}...937
    Fault tracing on hydraulic system_{49-50}...939
    High flow solenoid; description...942
    High flow solenoid; replacing...943
    Attachment bracket; operating_{47-59}...945
    Attachment bracket; operating_{47-23}...948
    Accumulator; replacing...951
    Accumulator; description...955
    Accumulator; specifications...957
  92 - MECHANICAL EQUIPMENT_ATTACHMENT...958
    Loader arm lift ram; description...959
    Loader Arm; Inspection...961
    Loader arm lift ram; removing...962
    Loader arm lift ram; installing...966
    Attachment bracket cylinder; removing...970
    Attachment bracket cylinder; installing...972
    Attachment bracket; removing...974
    Attachment bracket; installing...976
  94 - UNIT; LOAD HANDLING...979
    Loader arm solenoids; description...980
    Loader arm implement pilot solenoid; description...982
    Loader arm; removing...984
    Loader arm; installing...987
    Loader arm pivot pin; replacing...988
    Loader arm taper pin; adjusting...990
    Loader arm solenoid; replacing...995
    Loader arm implement pilot solenoid; replacing...997
    
Volvo Skid Steer Loaders MC135D Repair Service Manual

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