Volvo EC35C Compact Excavators Service Repair Manual
Volvo EC35C Compact Excavators Service Repair Manual
Complete service repair manual with Electrical Wiring Diagrams for Volvo EC35C Compact Excavators, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.
Volvo Construction Equipments EC35C 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.
PRODUCT DETAILS:
Total Pages: 1,691 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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
TABLE OF CONTENTS
0 - GENERAL
00 - DESCRIPTION; COMPLETE MACHINE
Component locations
Description, general
Product plate, description
00 - DESCRIPTION; COMPLETE MACHINE
03 - SPECIFICATIONS
Adjustable boom cylinder, specifications
Air conditioning unit, specifications
Alternator, specifications
Battery, specifications
Boom lifting cylinder, specifications
Bucket cylinder, specifications
Cab, tightening torques
Cab, weight
Control valve, tightening torques
Conversion tables
Cooling system, specification
Counterweight, specifications
Dimensions
Dipper arm cylinder, specifications
Dozer blade cylinder, specifications
Engine, capacities
Engine, specifications_{12-12-55}
Engine, specifications_{12-13-11}
Engine, tighten torques
Frame and track unit, specifications
Fuel feed pump, specifications
Fuel tank, volume
Hydraulic control unit, H-ECU, inputs and outputs
Hydraulic control unit, H-ECU, value list
Hydraulic system, specification
Hydraulic system, tightening torques
Hydraulic tank, specifications
Injectors, specification
Instrument panel, specifications
Lifting capacities
Light bulbs, specification
Lubrication system, specifications
Preheating, specifications_{12-09-13}
Preheating, specifications_{12-09-28}
Pump, specifications_{12-01-13}
Pump, specifications_{12-01-28}
Slew motor, specifications_{12-05-07}
Slew motor, specifications_{12-05-22}
Slew motor, tightening torques
Starter motor, specification
Tightening torques
Track motor, specifications
Track motor, tightening torques
Valve mechanism, specifications
V-ECU, I_O list
V-ECU, value list_{12-08-34}
V-ECU, value list_{12-08-50}
Weight
03 - SPECIFICATIONS
05 - TRANSPORT INSTRUCTIONS
Transporting and lifting the machine
05 - TRANSPORT INSTRUCTIONS
07 - STANDARD TIME
Operation numbers for additional work
07 - STANDARD TIME
08 - TOOL
E-4505
E-tool, 3501 Puller for gear wheel fan pump
Infrared Thermometer
08 - TOOL
09 - MISCELLANEOUS
Hydraulic cylinders, dieseling
Service position 2
Service position 3
Service positions
Welding on the machine
09 - MISCELLANEOUS
1 - STANDARD PARTS, SERVICE
16 - LUBRICANT; FUEL; OTHER FLUID
Alternative fuels
Coolant
Fuel, recommendation
Lubricants, specifications
16 - LUBRICANT; FUEL; OTHER FLUID
17 - SERVICE
Air cleaner primary filter, change
Air cleaner secondary filter, change
Battery condition, check
Cab main filter, replacing
Cleaning prior to repair
Cleanliness, braking and hydraulic system
Coolant, change
Coolant, changing
Coolant, level, check
Crankcase breather system, inspect
Creeping of hydraulic cylinder
Cylinder speed
Deviation when travelling straight ahead
Dust valve, clean
Engine, changing oil and filter
Engine, oil level, check
Engine radiator and hydraulic oil cooler, check (clean when necessary)
Fan belt and_or alternator belt, checking and adjusting tension
Fuel and fuel return hoses, replace
Fuel filter, change
Fuel injectors, inspect_clean and test
Fuel tank sediment, drain
Hoses for boom-, dipper-, and bucketcylinder, replace
Hoses on boom for X1, X2, X3, replace
Hydraulic oil filter, changing
Hydraulic oil level, check
Hydraulic oil tank, changing oil
Hydraulic pressure, checking
Hydraulic pump, suction hose and pressure hose, replace
Loose and loss of bolts, check
Lubrication and service schedules
Lubrication, see lubrication chart
Maintenance service, daily
Maintenance service, every 1000 hours
Maintenance service, every 1500 hours
Maintenance service, every 2000 hours
Maintenance service, every 250 hours
Maintenance service, every 3000 hours
Maintenance service, every 500 hours
Maintenance service, every 50 hours
Measuring condition
Quick coupler lock mechanism, replace
Repairing hydraulic system
Seat belt, replace
Service and maintenance
Service history (included in the respective Operator's manual), fill in
Slewing speed
Starting engine with booster cables
Test-run and check
The machine, check for external damages, cracks and wear damages
Thumb pivot pin, lubricating
Towing, measures
Track gearbox oil level, check
Track running speed
Track tension, adjusting
Track tension, checking_{10-56-46}
Track tension, checking_{10-57-09}
Travel motor gearbox, changing oil_{10-17-00}
Travel motor gearbox, changing oil_{10-17-29}
Travel Speed
Values, creeping of hydraulic cylinder
Values, cylinder speed
Values, deviation when travelling straight ahead
Values, slewing speed
Values, track running speed
Values, travel speed
Valve clearance, checking and adjusting
Warranty inspection 1000 hours
Warranty inspection 100 hours
Water separator, drain
Water separator filter element, change
17 - SERVICE
19 - GENERAL
CE marking and declaration of conformity
Checklist after a fire or heat exposure
Decontamination
Environmental handling for the future
Environmentally hazardous fluids
Environmentally safe handling
Fire prevention measures
Health hazards with paint, plastics and rubber
Pressure setting and leak detection
Safety concerns everybody!
Safety for work on hydraulic systems
Safety rules when servicing
Safety when handling oils and fuel
Safety when handling the machine
Safety when lifting and supporting the machine
Safety when working with air conditioning refrigerant
Safety when working with batteries
Starting with booster batteries
Waste handling
Working in environmentally contaminated areas
Working on the electrical system of the machine
19 - GENERAL
2 - ENGINE WITH MOUNTING AND EQUIPMENT
20 - GENERAL
Engine, capacities
Engine, description_{09-13-31}
Engine, description_{09-14-04}
Engine, description_{09-14-37}
Engine, description_{09-15-18}
Engine, description_{09-15-54}
Engine, description_{09-16-34}
Engine, tighten torques
20 - GENERAL
21 - ENGINE
Camshaft, description
Crankshaft, description
Crankshaft front oil seal, replacing
Cylinder block, description-[5440]
Cylinder block, description
Cylinder compression, testing
Cylinder head, description-[5606]
Cylinder head, description
Engine, installing
Engine, removing
Engine, specifications_{09-10-40}
Engine, specifications_{09-11-47}
Pistons, description-[5343]
Pistons, description
Timing gear, description
Valve cover, description and operation
Valve covers, fitting new gasket_{08-40-18}
Valve covers, fitting new gasket_{08-41-58}
Valve mechanism, description-[5240]
Valve mechanism, description
Valve mechanism, specifications
Valves, adjusting
21 - ENGINE
22 - LUBRICATING SYSTEM
Lubrication system, description
Lubrication system, specifications
Oil pump, description_{08-32-37}
Oil pump, description_{08-33-04}
Oil pump, replacing_{08-28-37}
Oil pump, replacing_{08-32-02}
22 - LUBRICATING SYSTEM
23 - FUEL SYSTEM
Fuel feed pump, description
Fuel feed pump, specifications
Fuel filter_water separator, description
Fuel pump, installing
Fuel pump, removing
Fuel system, description
Fuel tank, description
Fuel tank, installing
Fuel tank, removing
Fuel tank, volume
Idling speed, checking and adjusting
Injection pump, removing
Injection timing, checking
Injectors, description
Injectors, specification
23 - FUEL SYSTEM
25 - INLET & EXHAUST SYSTEM
Air cleaner, description
Air cleaner, installing
Air cleaner, removing
Preheating coil, replacing
Preheating, specifications-[0017]
Schematic
Silencer, installing
Silencer, removing
25 - INLET & EXHAUST SYSTEM
26 - COOLING SYSTEM
Alternator, specifications-[5147]
Coolant pump, installing
Coolant pump, removing
Cooling system, description
Cooling system, specification
Fan belt and_or alternator belt, checking and adjusting tension
Fan belt and_or alternator belt, replacing
Radiator, installing
Radiator, removing
Thermostat, replacing
26 - COOLING SYSTEM
27 - ENGINE CONTROL
Auto idling device, description
Automatic idling device, installing
Automatic idling device, removing
Cold start device, description
27 - ENGINE CONTROL
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS
30 - GENERAL
Checking electrical cabling and connectors
Collection of basic data
DC current measurement
DC voltage measurement
Diode check procedure
Electrical system, special instructions for servicing, action when working on machine
Electrical system, special instructions for servicing, electrical components, batteries
Electrical system, special instructions for servicing, electronic components
Electrical system, special instructions for servicing, general
Hydraulic control unit, H-ECU, functions check
Hydraulic control unit, H-ECU, value list
Measuring components
Resistance measurement
Troubleshooting, assistant devices
Troubleshooting, general
Troubleshooting tips
V-ECU, value list_{10-38-55}
V-ECU, value list_{10-39-10}
Vehicle ECU functions, check
30 - GENERAL
31 - BATTERY
Batteries, replacing
Battery condition, checking
Battery, specifications
31 - BATTERY
32 - ALTERNATOR; CHARGE REGULATOR
Alternator, installing
Alternator, removing
Alternator, specifications
32 - ALTERNATOR; CHARGE REGULATOR
33 - STARTING SYSTEM
Glow plug, installing
Glow plug, removing
Preheating, specifications
Starter motor, installing
Starter motor, removing
Starter motor, specification
33 - STARTING SYSTEM
35 - LIGHTING
Light bulb, replacing
Light bulbs, specification
35 - LIGHTING
36 - OTHER ELECTRICAL EQUIPMENT
Antitheft device, first activation of a new A-ECU
Horn, replacing
Option anti-theft, instruction
V-ECU, replacing
Vehicle control unit V-ECU, description
36 - OTHER ELECTRICAL EQUIPMENT
37 - CABLE; FUSE; RELAY
Cable and component marking explanations
Cable harnesses, description_{08-53-28}
Cable harnesses, description_{08-54-30}
Cable harnesses, description_{09-51-23}
Cable harnesses, description_{09-51-24}
Cable harnesses, description_{09-57-11}
Cable harnesses, description_{10-01-23}
Cable harnesses, description_{10-04-02}
Cable harnesses, description_{10-04-45}
Cables, description_{10-20-55}
Cables, description_{10-21-13}
Component list Alternator, batteries, capacitors, electronic units, voltage outlet
Component list Control lights_warning lights
Component list Fuses
Component list, Heating coils
Component list, lights
Component list, motors
Component list Relays_{10-18-25}
Component list Relays_{10-18-39}
Component list, sensors_{10-17-49}
Component list, sensors_{10-18-03}
Component list Solenoid valves
Component list, Sounders
Component list Switches
Component locations_{04-47-34}
Component locations_{04-47-50}
Component locations_{04-48-11}
Component locations_{04-48-27}
Component locations_{04-49-35}
Component locations_{04-49-53}
Component locations_{04-50-38}
Component locations_{04-50-51}
Component locations-[4714]
Component locations-[4851]
Component locations-[4916]
Component locations-[5015]
Component locations
Electrical distribution box, circuit board replacing
Electrical symbols and designation
Fuse, description
Hydraulic control unit, H-ECU, inputs and outputs
Wiring diagram 10_{10-05-56}
Wiring diagram 10_{10-06-13}
Wiring diagram 1_{10-15-23}
Wiring diagram 1_{10-15-43}
Wiring diagram 11_{10-05-16}
Wiring diagram 11_{10-05-33}
Wiring diagram 2_{10-14-35}
Wiring diagram 2_{10-14-55}
Wiring diagram 3_{10-13-42}
Wiring diagram 3_{10-14-04}
Wiring diagram 4_{10-12-51}
Wiring diagram 4_{10-13-11}
Wiring diagram 5_{10-10-18}
Wiring diagram 5_{10-10-41}
Wiring diagram 6_{10-09-19}
Wiring diagram 6_{10-09-41}
Wiring diagram 7_{10-08-25}
Wiring diagram 7_{10-08-48}
Wiring diagram 8_{10-07-30}
Wiring diagram 8_{10-07-52}
Wiring diagram 9_{10-06-41}
Wiring diagram 9_{10-07-00}
Wiring diagram, general
37 - CABLE; FUSE; RELAY
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
Instrument panel, description
Instrument panel, operation
Instrument panel, specifications
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM
4 - POWER TRANSMISSION
40 - GENERAL
General notes to be observe when working on power transmission assemblies
40 - GENERAL
44 - HYDROSTATIC DRIVE
Check the static brake torque
Gear motor, exploded view
Slew motor, break release valve_{02-49-24}
Slew motor, break release valve_{02-49-35}
Slew motor, description_{04-33-15}
Slew motor, description_{04-33-47}
Slew motor, description_{04-34-21}
Slew motor, description_{04-34-52}
Slew motor, specifications_{04-32-30}
Slew motor, specifications_{04-32-42}
Slew motor, tightening torques
Slew motor, troubleshooting
Swing motor, installing_{04-30-03}
Swing motor, installing_{04-30-25}
Swing motor removed, overhaul
Swing motor, removing_{04-30-55}
Swing motor, removing_{04-31-20}
Swing motor, removing_{04-31-37}
Swing motor, replacing counterbalance valve_{02-50-09}
Swing motor, replacing counterbalance valve_{02-50-39}
Swing motor, replacing counterbalance valve_{02-50-54}
Swivel joint, description
Track motor, installing
Track motor, removing
Track motor, specifications
Track motor, tightening torques
Track motor, troubleshooting
Travel gear, dismantling
Travel motor, assembly
Travel motor, description
Travel motor, exploded view
44 - HYDROSTATIC DRIVE
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT
70 - GENERAL
Frame and track unit, specifications
70 - GENERAL
71 - FRAME
Counterweight, description
Counterweight, installing
Counterweight, removing
Counterweight, specifications
Undercarriage, description
71 - FRAME
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
Bottom roller, installing
Bottom roller, removing-[4018]
Bottom roller, removing
Front idler, installing
Front idler, removing-[4410]
Front idler, removing-[4425]
Front idler, removing-[4439]
Front idler, removing
Rubber track, installing
Rubber track, removing-[4225]
Rubber track, removing
Sprocket, installing
Sprocket, removing-[4312]
Sprocket, removing
Top roller, installing
Top roller, removing-[4128]
Top roller, removing
77 - WHEELS; TRACKS; TYRE; HUB; DRUM
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
81 - CAB, NAKED; CANOPY
Cab, installing
Cab platform, installing_{01-50-28}
Cab platform, installing_{01-51-29}
Cab platform, removing_{02-33-34}
Cab platform, removing_{02-34-53}
Cab platform, removing_{02-35-56}
Cab, removing
Cab, roof panel, installing
Cab, roof panel, removing
Cab, tightening torques
Cab, weight
81 - CAB, NAKED; CANOPY
82 - ENGINE HOOD; MUDGUARD; FOOT STEP
Engine hood, changing gas spring
82 - ENGINE HOOD; MUDGUARD; FOOT STEP
85 - CAB INTERIOR; UPHOLSTERY
Operator's seat, installing
Operator's seat, removing
Seat retention cable, replacing
85 - CAB INTERIOR; UPHOLSTERY
87 - AIR CONDITIONING UNIT
Air conditioning unit, specifications
87 - AIR CONDITIONING UNIT
88 - INTERIOR EQUIPMENT
Instrument console, installing
Instrument console, removing
Seat safety belt, replacing
88 - INTERIOR EQUIPMENT
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS
90 - GENERAL
General notes when working on hydraulic system
H-ECU (hydraulic), replacing pre-programmed ECU
Hydraulic components, storing and transporting
Hydraulic oil, description
Hydraulic oil, storage and handling
Hydraulic system, specification
Hydraulic system, tightening torques
Pressure adjustment and leaks checking
90 - GENERAL
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
Accumulator, description
Balancing valve on offset cylinder
Compensator valve, replacing_{12-39-14}
Compensator valve, replacing_{12-39-36}
Control lever, installing
Control lever, removing_{12-19-43}
Control lever, removing_{12-20-10}
Control levers, description
Control levers, maintenance standard
Control levers, repairing
Control valve, tightening torques
Directional valve, dozer blade, disassembling spool and replacing seals_{12-41-14}
Directional valve, dozer blade, disassembling spool and replacing seals_{12-41-44}
Directional valve, drive, disassembling spool and replacing seals_{12-42-26}
Directional valve, drive, disassembling spool and replacing seals_{12-42-59}
Directional valve, hydraulically operated, disassembling spool and replacing seals_{12-43-43}
Directional valve, hydraulically operated, disassembling spool and replacing seals_{12-44-16}
Flow regulation valve, changing_{12-45-54}
Flow regulation valve, changing_{12-46-22}
FR pressure control valve, checking and adjusting
Hydraulic diagram 10
Hydraulic diagram 11
Hydraulic diagram 12
Hydraulic diagram 1
Hydraulic diagram 2
Hydraulic diagram 3
Hydraulic diagram 4
Hydraulic diagram 5
Hydraulic diagram 6
Hydraulic diagram 7
Hydraulic diagram 8
Hydraulic diagram 9
Hydraulic diagram, complete_{12-56-01}
Hydraulic diagram, complete_{12-56-23}
Hydraulic diagram, control pattern selector valve
Hydraulic diagram, swing system_{01-05-44}
Hydraulic diagram, travel_{01-04-29}
Hydraulic diagram, travel_{01-04-51}
Hydraulic oil cooler, description
Hydraulic oil cooler, installing
Hydraulic oil cooler, removing
Hydraulic pump, power control, adjusting
Hydraulic pump, power control, checking
Hydraulic pump, standby pressure, checking and adjusting
Hydraulic tank, specifications
Load check valve, replacing_{12-40-10}
Load check valve, replacing_{12-40-33}
LR pressure relief valve, checking and adjusting
LS (load sense) pressure, checking_{12-36-26}
LS (load sense) pressure, checking_{12-36-49}
LS-pressure relief valve, replacing_{12-46-57}
LS-pressure relief valve, replacing_{12-47-21}
LS system, bleeding
Main control valve, assembling_{12-47-55}
Main control valve, assembling_{12-48-19}
Main control valve, description_{12-53-00}
Main control valve, description_{12-53-23}
Main control valve, disassembling_{12-48-52}
Main control valve, disassembling_{12-49-15}
Main control valve, installing_{12-49-54}
Main control valve, installing_{12-50-20}
Main control valve, removing_{12-51-06}
Main control valve, removing_{12-51-38}
Main control valve, removing_{12-52-03}
Main control valve troubleshooting
Port relief valve pressure, checking and adjusting_{12-38-17}
Port relief valve pressure, checking and adjusting_{12-38-40}
Proportional valve, right _ left selector
Pump, installing
Pump, removing
Pump, specifications_{12-33-41}
Pump, specifications_{12-34-00}
Pump, troubleshooting
Secondary pressure limiting valve, replacing_{12-44-52}
Secondary pressure limiting valve, replacing_{12-45-16}
Servo accumulator, installing_{12-24-18}
Servo accumulator, installing_{12-24-41}
Servo accumulator, removing_{12-25-14}
Servo accumulator, removing_{12-25-36}
Servo pressure, checking and adjusting
Servo valve, description
Servo valve, installing
Servo valve, removing_{12-27-43}
Servo valve, removing_{12-28-05}
Shuttle valve, swing brake
Six way valve, offset_optional equipment
This information is not valid for serial number range_{01-05-21}
This information is not valid for serial number range_{12-22-30}
This information is not valid for serial number range_{12-23-22}
Travel valve (pedal), installing_{12-22-52}
Travel valve (pedal), removing_{12-23-45}
Working pressure, checking and adjusting
91 - WORKING HYDRAULIC; SERVO HYDRAULICS
92 - MECHANICAL EQUIPMENT_ATTACHMENT
Boom support, pivot play
Thumb kit, description
92 - MECHANICAL EQUIPMENT_ATTACHMENT
97- UNIT, DIGGING
Adjustable boom cylinder, specifications
Boom cylinder, installing
Boom cylinder, removing_{12-12-09}
Boom cylinder, removing_{12-12-33}
Boom, installing
Boom lifting cylinder, specifications
Boom, removing_{12-14-00}
Boom, removing_{12-14-32}
Boom, removing_{12-14-33}
Bucket cylinder, installing
Bucket cylinder, removing_{12-07-26}
Bucket cylinder, removing_{12-07-49}
Bucket cylinder, specifications
Dipper arm cylinder, installing
Dipper arm cylinder, removing_{12-08-58}
Dipper arm cylinder, removing_{12-09-21}
Dipper arm cylinder, specifications
Dipper arm, installing
Dipper arm, removing_{12-10-31}
Dipper arm, removing_{12-10-58}
97- UNIT, DIGGING
99 - MISCELLANEOUS
Injection pump, description
Injection pump, removing
99 - MISCELLANEOUS
