Volvo Skid Steer Loaders MC135D Repair Service Manual
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
