Volvo ECR35D Compact Excavators Service Repair Manual
Complete repair service manual with Electrical Wiring Diagrams for Volvo ECR35D Compact Excavators, with all the technical information to maintain, diagnose, and repair like professional mechanics.
Volvo Constructions ECR35D 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.
Volvo ECR35D Compact Excavators Service Repair Manual.pdf
Total Pages: 1,309
File Format: PDF (Windows & Mac & Linux)
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
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..2
00 - DESCRIPTION; COMPLETE MACHINE..3
Description; general..4
Product plate; description..6
Component locations..8
03 - SPECIFICATIONS..9
Tightening torques ..10
Conversion tables..21
Weight..26
Lifting capacities..27
Capacities..28
07 - STANDARD TIME..29
Operation numbers for additional work..30
08 - TOOL..32
Infrared Thermometer..33
09 - MISCELLANEOUS..37
Welding on the machine..38
Hydraulic cylinders; dieseling..39
1 - STANDARD PARTS; SERVICE..41
16 - LUBRICANT; FUEL; OTHER FLUID..42
Hydraulic oil..43
Recommended lubricants..48
Fuel; recommendation..51
Coolant ..52
Coolant..57
Alternative fuels..59
17 - SERVICE..62
Cleanliness; braking and hydraulic system..65
Hydraulic system; pressure release..66
Repairing hydraulic system..68
Service..69
Service and maintenance..72
Cleaning prior to repair..74
Arrival Inspection; according to Inspection Programme..75
Delivery Inspection; according to Inspection Programme..76
Maintenance of Stored Machines; according to Inspection Programme..77
Service position 1 ..78
Service position 2 ..79
Service position 3 ..81
Maintenance service; first 50 hours..83
Maintenance service; daily..85
Maintenance service; every 50 hours..87
Maintenance service; every 250 hours..89
Maintenance service; every 500 hours..92
Maintenance service; every 1000 hours..95
Maintenance service; every 1500 hours..99
Maintenance service; every 2000 hours..100
Maintenance service; every 3000 hours..102
Fuel filter; replacing..104
Valves; adjusting ..106
Coolant; changing ..110
Machine condition; checking..113
Thumb pivot pin; lubricating..114
Radiator and hydraulic oil cooler; cleaning..116
Hydraulic pressure; checking..118
Leakage oil filter element; replacing..122
Seat belt; replacing..124
Injection timing; checking ..127
Injection pump; checking..133
Test running and checking..139
Lubrication..140
Crankcase ventilation separator; checking..141
Engine oil level; checking..143
Engine oil and filter; changing..145
Water separator; checking..148
Water separator; cleaning..150
Fuel hoses; checking..152
Fuel injectors; checking..153
Air inlet hose; checking..162
Exhaust manifold; checking..163
Engine air cleaner primary filter; cleaning_{47-31}..164
Engine air cleaner primary filter; cleaning_{47-06}..167
Engine air cleaner primary filter; replacing_{46-29}..171
Engine air cleaner primary filter; replacing_{46-05}..174
Engine air cleaner secondary filter; replacing_{45-28}..177
Engine air cleaner secondary filter; replacing_{45-04}..179
Engine air cleaner secondary filter; replacing_{44-20}..181
Coolant level; checking..183
Coolant freezing point; checking..185
Fan_alternator belt; checking..187
Radiator hoses; checking..189
Travel gearbox oil level; checking..191
Travel gearbox oil; changing..193
Track tension and condition; checking..195
Cab main filter; replacing..198
Hydraulic oil level; checking..200
Hydraulic oil; changing..202
Hydraulic oil return filter; replacing..205
Hydraulic hoses; checking..207
Attachment quick coupler; checking..208
Service history (included in the respective Operator's manual); fill in...209
Lubrication and service schedules..210
Measuring condition..213
Cylinder speed..214
Values; cylinder speed..218
Creeping of hydraulic cylinder..219
Values; creeping of hydraulic cylinder..221
Slewing speed..222
Values; slewing speed..224
Travel Speed..225
Values; travel speed..227
Track running speed..228
Values; track running speed..230
Deviation when travelling straight ahead..231
Values; deviation when travelling straight ahead..234
Towing; measures..235
Starting with booster batteries ..237
19 - GENERAL..238
Safety concerns everybody!..239
Service position 1..241
Service position 2..243
Service position 3..245
CE marking and declaration of conformity..247
Safety when handling the machine..249
Safety rules when servicing..254
Safety when lifting and supporting the machine..257
Fire prevention measures..259
Working on the electrical system of the machine..262
Safety when working with batteries..264
Starting with booster batteries..267
Safety when handling oils and fuel..269
Pressure setting and leak detection..270
Safety for work on hydraulic systems..271
Checklist after a fire or heat exposure..273
Health hazards with paint; plastics and rubber..274
Environmental handling for the future..276
Waste handling..278
Environmentally safe handling..282
Environmentally hazardous fluids..284
Safety when working with air conditioning refrigerant..285
Working in environmentally contaminated areas..288
Decontamination..291
2 - ENGINE WITH MOUNTING AND EQUIPMENT..292
20 - GENERAL..293
Engine; description_{11-45}..294
Engine; description_{11-14}..297
Engine; description_{10-49}..300
Engine; capacities..303
Engine; tighten torques_{09-51}..304
Engine; tighten torques_{09-29}..306
Troubleshooting chart..308
21 - ENGINE..311
Engine; specifications_{08-23}..312
Engine; specifications_{08-01}..314
Engine; removing..316
Engine; installing..323
Cylinder head; description..329
Cylinder head; removing..331
Cylinder head; installing..337
Valve mechanism; description..343
Valve system specifications..345
Valve cover; removing..346
Valve cover; installing..348
Valves; adjusting..350
Timing gear case new gasket; installing..355
Crankshaft; description_58-46..368
Crankshaft; description..370
Crankshaft front oil seal; replacing..372
Crankshaft rear oil seal; replacing..378
Oil sump; replacing..382
Engine mounts; replacing..384
22 - LUBRICATING SYSTEM..386
Lubricating system; description..387
Lubrication system; specifications..390
Lubrication system; tightening torques..391
Lubrication system; component locations..392
Oil pump; description..394
Oil pump; replacing..395
Lubrication oil pressure; checking with pressure gauge..399
23 - FUEL SYSTEM..402
Fuel system; description..403
Fuel system; general specifications_{49-26}..405
Fuel system; general specifications_{49-05}..406
Fuel feed pump; description..407
Fuel filter_water separator; description..408
Fuel feed pump; specifications..409
Fuel pump; removing..410
Fuel pump; installing..413
Fuel tank; specifications..415
Fuel tank; description..416
Fuel tank; removing..417
Fuel tank; installing..421
Fuel pipes; replacing..424
Injection pump gasket shims; description..431
Injection pump; description..433
Injection pump; fitting incl setting injection timing..436
Idling speed; checking and adjusting..441
Injection timing; checking..444
Injection pump; removing..449
Injectors; specification..452
Injectors; description..453
Injectors; replacing..455
Injectors; checking..458
25 - INLET & EXHAUST SYSTEM..461
Intake and exhaust system; description..462
Silencer; removing..464
Silencer; installing..467
Exhaust pipe; replacing..470
Air cleaner; specification..473
Air cleaner; description..474
Air cleaner; removing..476
Air cleaner; installing..478
Air cleaner; primary filter replacing..479
Air cleaner; secondary filter replacing..482
26 - COOLING SYSTEM..484
Cooling system; description..485
Cooling system; specification..487
Cooling system; component location..488
Coolant; changing..489
Coolant anti-freeze resistance; checking..492
Radiator hoses all; replacing..494
Expansion tank; removing..496
Expansion tank; installing..498
Radiator; removing..499
Radiator; installing..500
Coolant pump; replacing..501
Thermostat; replacing..505
Fan belt and_or alternator belt; checking and adjusting tension..507
Fan belt and_or alternator belt; replacing..510
27 - ENGINE CONTROL..513
Auto idling device; description..514
Automatic idling device; removing..516
Automatic idling device; installing..518
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS..520
30 - GENERAL..521
Electrical system; special instructions for servicing; general..524
Electrical system; special instructions for servicing; electronic components_{16-43}..526
Electrical system; special instructions for servicing; electronic components_{16-18}..528
Electrical system; special instructions for servicing; electronic components_{15-57}..529
Electronic control system; description..531
Communication with data buses..533
Data buses; function..534
Service connection and programming connection..539
Data links; fault tracing with Oscilloscope..541
Software parameters; description..551
General fault diagnosis information..554
Troubleshooting strategy..555
Troubleshooting; general..557
Troubleshooting tips..559
Troubleshooting; assistant devices..561
Collection of basic data..563
Information display; check..565
Error code information; general..566
Error codes; build-up ..568
Conditions when checking..573
Measuring components..578
Lead and connector checks..579
Electrical cables and connectors; checking..585
Checking electrical cabling and connectors..590
Troubleshooting tools..595
Special tools for troubleshooting..596
VCADS Pro service tool..597
Tech Tool; operations..601
AL3201; description and measuring..602
BA3101; description and measuring..605
CU2504; description and measuring..607
FX1056; description and measuring..610
FX1057; description and measuring..612
MA2307; description and measuring..614
MA4228; description and measuring..616
MA8704; description and measuring..618
MA9109; description and measuring..620
MA9186; description and measuring..622
RE3301; description and measuring..624
SAE J1708_1587 Information link; description and measuring..626
SAE J1939_CAN control link; description and measuring..628
SAE J1939_CAN2 Control link; description and measuring..631
SE8702; description and measuring..634
Resistance measurement..637
DC voltage measurement..640
DC current measurement..643
Diode check procedure..647
VCADS Pro; connecting problems..650
Connecting special tools..653
999 8699 Multi-pin breaker box..656
999 0062 Extension cable..657
8883 0028 Adapter cable..658
88890040 Oscilloscope for VCADS Pro..659
999 3894 Template..660
11 666 140 Multimeter..661
Measuring; general..662
Measuring symbols; description..663
Component descriptions..666
Component troubleshooting; structure; description..669
Component troubleshooting; checking wiring harness and input_output on ECU..671
Component troubleshooting; checking component..673
Component troubleshooting; checking subsystem (circuit)..675
Error codes; build-up..677
Error code information; description..681
31 - BATTERY..683
Battery; description..684
Battery; specifications..685
Battery condition; checking..686
Batteries; replacing..690
32 - ALTERNATOR; CHARGE REGULATOR..693
Alternator; specifications..694
Alternator; removing..695
Alternator; installing..698
33 - STARTING SYSTEM..701
Starter motor; specification..702
Starter motor; removing..703
Starter motor; installing..705
Preheating; specifications_{23-12}..707
Preheating; specifications_{22-50}..708
Glow plug; removing..709
Glow plug; installing..711
Glow plugs; testing..713
35 - LIGHTING..714
Light bulbs; specification..715
Light bulb; replacing..716
36 - OTHER ELECTRICAL EQUIPMENT..720
Horn; replacing..721
Travel alarm; replacing..724
Instrument control unit I-ECU; functional description..726
Vehicle control unit V-ECU; functional description..728
I-ECU; replacing..729
V-ECU; replacing..731
Theft protection..733
Cable and component marking explanations..734
37 - CABLE; FUSE; RELAY..736
Explanation of wiring diagrams..739
Electrical system component locations..743
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{11-21}..744
Component list Alternator; batteries; capacitors; electronic units; voltage outlet_{10-59}..746
Component list; Antennas (Care Track)_{10-26}..747
Component list; Antennas (Care Track)_{10-04}..748
Component list Fuses_{09-31}..749
Component list Fuses_{09-10}..751
Component list; Heating coils..753
Component list Motors; resistors; monitoring system_{08-04}..754
Component list Motors; resistors; monitoring system_{07-42}..755
Component list Relays_{07-09}..756
Component list Relays_{06-48}..757
Component list; sensors_{06-14}..758
Component list; sensors_{05-53}..759
Component list Solenoid valves_{05-20}..760
Component list Solenoid valves_{04-58}..761
Component list; Sounders_{04-25}..762
Component list; Sounders_{04-03}..763
Component list Switches_{03-30}..764
Component list Switches_{03-09}..765
I-ECU; I_O list_{02-30}..766
I-ECU; I_O list_{02-08}..768
K-ECU; I_O list..769
V-ECU; I_O list..770
Wiring diagram 1_{00-44}..772
Wiring diagram 1_{00-23}..773
Wiring diagram 2_{59-50}..774
Wiring diagram 2_{59-25}..777
Wiring diagram 3_{58-48}..780
Wiring diagram 3_{58-24}..782
Wiring diagram 4_{57-47}..785
Wiring diagram 4_{57-23}..788
Wiring diagram 5_{56-40}..791
Wiring diagram 5_{56-15}..793
Wiring diagram 6_{55-38}..795
Wiring diagram 6_{55-14}..798
Wiring diagram 7_{54-37}..801
Wiring diagram 7_{54-12}..803
Wiring diagram 8_{53-24}..805
Wiring diagram 8_{52-59}..807
Wiring diagram 9_{52-23}..809
Wiring diagram 9_{51-58}..811
Wiring diagram 10_{51-22}..813
Wiring diagram 10_{50-57}..816
Wiring diagram 11_{50-21}..819
Wiring diagram 11_{49-56}..821
Wiring diagram 12_{49-20}..823
Wiring diagram 12_{48-55}..825
Wiring diagram 13..827
Wiring diagram 14..829
Wiring diagram 15..831
Electrical distribution box; circuit board replacing..833
Electrical distribution box..835
Antennas (Caretrack); component locations..836
Component location; alternator; batteries; capacitors; electronic units; voltage outlet_{44-20}..837
Component location; alternator; batteries; capacitors; electronic units; voltage outlet_{43-55}..839
Component location; fuses_{43-19}..841
Component location; fuses_{42-54}..842
Component location; motors_{42-18}..843
Component location; motors_{41-54}..845
Component location; relays_{41-12}..846
Component location; relays_{40-47}..848
Component location; sensors_{40-10}..849
Component location; sensors_{39-46}..851
Component location; solenoid valves_{38-58}..853
Component location; solenoid valves_{38-33}..856
Component location; switches_{37-57}..858
Component location; switches_{37-32}..860
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM..862
Keypad; description..863
Service mode..866
39 - MISCELLANEOUS..873
CareTrack system; description..874
CareTrack W-ECU; description..876
W-ECU; MID142; changing non-programmed ECU_{33-09}..880
W-ECU; MID142; changing non-programmed ECU_{32-45}..882
4 - POWER TRANSMISSION..885
40 - GENERAL..886
General notes to be observe when working on power transmission assemblies..887
Power transmission; description..889
44 - HYDROSTATIC DRIVE..890
Track motor; tightening torques..891
Track motor; specifications..892
Swing motor; specifications..893
Swing motor; description..894
Swing motor; removing..899
Swing motor; installing..902
Travel motor; description..905
Travel motor; exploded view..911
Track motor; removing..913
Track motor; installing..917
Centre passage; description..921
Centre passage; removing..924
Centre passage; installing..928
49 - MISCELLANEOUS..932
Tightening torques..933
Swing ring gear; description..934
Swing ring; removing..936
Swing ring; installing..941
7 - FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL_TRACK UNIT..945
70 - GENERAL..946
Frame and track unit; specifications..947
Tightening torques..948
71 - FRAME..949
Counterweight; specifications..950
Additional counterweight; description..951
Counterweight; description..952
Counterweight; tightening torques..953
Additional counterweight; removing..954
Additional counterweight; installing..957
Counterweight; removing..959
Counterweight; installing..962
Undercarriage; description..965
77 - WHEELS; TRACKS; TYRE; HUB; DRUM..966
Front idler; removing..967
Front idler; installing..969
Sprocket; removing..971
Rubber track; removing..972
Rubber track; installing..975
Top roller; removing..976
Top roller; installing..979
Bottom roller; removing..982
Bottom roller; installing..984
8 - MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE..986
81 - CAB; NAKED; CANOPY..987
Cab; weight..988
Cab; tightening torques..989
Cab; removing..990
Cab; installing..994
Cab platform; removing..998
Cab platform; installing..1005
Cab; roof panel; removing..1013
Cab; roof panel; installing..1015
Cab; position 1..1017
Cab; position 1; restoring..1020
82 - ENGINE HOOD; MUDGUARD; FOOT STEP..1023
Engine hood; replacing..1024
Engine hood; changing gas spring..1026
85 - CAB INTERIOR; UPHOLSTERY..1028
Operator's seat; removing..1029
Operator's seat; installing..1031
87 - AIR CONDITIONING UNIT..1033
Air conditioning unit; specifications..1034
Cooling unit; performance test..1036
88 - INTERIOR EQUIPMENT..1042
Seat safety belt; replacing..1043
9 - HYDRAULIC SYSTEM; DIGGING_HANDLING_GRADING EQUIPMENT; MISCELLANEOUS..1046
91 - WORKING HYDRAULIC; SERVO HYDRAULICS..1047
Hydraulic diagram; complete - Image..1050
Explanations to hydraulic diagram..1052
Cleanliness when working on hydraulic components..1059
Hydraulic diagram; complete_{48-11}..1060
Hydraulic diagram; complete_{47-49}..1063
Hydraulic diagram; schematic..1066
Hydraulic diagram; control pattern selector valve..1068
Hydraulic system; description..1071
General notes when working on hydraulic system..1075
Hydraulic system; repair of hydraulic components in workshop..1077
Pressure adjustment and leaks checking..1078
Hydraulic oil; storage and handling..1079
Hydraulic components; storing and transporting..1080
Hydraulic system; tightening torques..1081
Hydraulic system; specification..1082
LS system; bleeding..1083
Hydraulic tank; specifications..1085
Hydraulic oil cooler; description..1086
Hydraulic oil tank; removing..1087
Hydraulic oil tank; installing..1090
Hydraulic oil cooler; removing..1093
Hydraulic oil cooler; installing..1095
Main control valve; description..1097
Control valve; tightening torques..1100
Main control valve; removing..1102
Main control valve; installing..1106
Main control valve; disassembling..1109
Main control valve; assembling..1112
LS-pressure relief valve; replacing..1116
Secondary pressure limiting valve; replacing..1119
Port relief valve pressure; checking and adjusting..1123
Working pressure; checking and adjusting..1126
Hose rupture valves..1129
Hose rupture valve; installing..1131
Pump; specifications_{32-28}..1133
Pump; specifications_{32-07}..1135
Hydraulic pump; description..1137
Pump; troubleshooting..1152
Pump; removing..1154
Pump; installing..1156
LS (load sense) pressure; checking..1159
Hydraulic pump; power control; checking..1162
Hydraulic pump; power control; adjusting..1168
Hydraulic pump; standby pressure; checking and adjusting..1171
FR pressure control valve; checking and adjusting..1174
LR pressure relief valve; checking and adjusting..1177
Servo valve; removing..1181
Servo valve; installing..1183
Servo pressure; checking and adjusting..1186
Accumulator; description..1189
Accumulator; replacing..1190
Travel valve (pedal); removing..1192
Travel valve (pedal); installing..1195
Control levers; maintenance standard..1197
Control levers; repairing..1199
Left control lever; removing..1207
Right control lever; removing..1210
Left control lever; installing..1213
Right control lever; installing..1216
Control pattern selector valve; description..1219
Hydraulic diagram; X1 line..1223
Control pattern selector valve; removing..1228
Control pattern selector valve; installing..1230
92 - MECHANICAL EQUIPMENT_ATTACHMENT..1231
Boom support; pivot play..1232
Steelwrist quick coupler..1237
Quickfit; function check..1242
Thumb kit; description..1244
97 - UNIT; DIGGING..1246
Boom lifting cylinder; specifications..1247
Dipper arm cylinder; specifications..1248
Bucket cylinder; specifications..1249
Adjustable boom cylinder; specifications..1250
Dozer blade cylinder; specifications..1251
Boom; removing..1252
Boom; installing..1259
Boom cylinder; removing..1266
Boom cylinder; installing..1270
Dipper arm; removing..1274
Dipper arm; installing..1279
Dipper arm cylinder; removing..1283
Dipper arm cylinder; installing..1287
Bucket cylinder; removing..1291
Bucket cylinder; installing..1295
98 - FUNCTION FOR ROAD CONSTRUCTION..1299
Dozer blade cylinder; replacing..1300
Volvo ECR35D Compact Excavators Service Repair Manual
