Volvo BM A35 Articulated Hauler Workshop Repair Service Manual PDF - MVOLCONA35BM.zip
A full service and repair guide, complete with electrical wiring schematics, for the Volvo BM A35 Articulated Hauler — offering the technical detail needed to service, troubleshoot, and maintain the machine the way a professional technician would.
The Volvo BM A35 Articulated Hauler workshop service & repair manual contains:
* 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.
Articulated Haulers A35 Volvo BM Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,221 pages
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
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 - Foreword......2
0 - GENERAL......3
00 - DESCRIPTION; COMPLETE MACHINE......4
Description......4
03 - SPECIFICATIONS......5
Machine type plates and PIN......5
Volvo standard tightening torques......7
08 - TOOL......9
Drawings of E-tools that can be made in your own workshop......9
Multi-pin breaker box (part no. 11 668 001)......32
Multi-pin breaker box (part no. 11 668 002)......34
Recycling station (part no. 11 666 070)......36
Recycling station FRS-10GS part no. 981 2443......38
Scales 981 2444......40
1 - STANDARD PARTS, SERVICE......42
10 - General......43
Recovering......43
Towing of machine......44
16 - LUBRICANT; FUEL; OTHER FLUID......45
Brake oil and pressure filter, changing (serial no. 1827)......45
17 - SERVICE......49
Cleanliness, brake and hydraulic systems......49
Electric welding......50
19 - GENERAL......51
Batteries......51
Before operating......52
Charging of batteries......54
Fire prevention measures......55
General......58
Lifting the machine......59
Refrigerant......63
Risks in connection with polymer materials......65
Rules when servicing......67
Starting with booster batteries......73
Tires......74
Transporting the machine......75
Upon completion of service or when the machine is not to be operated for a longer period of time......78
When the engine is running......79
When there is a risk of overturning......80
2 - ENGINE WITH MOUNTING AND EQUIPMENT......81
20 - GENERAL......82
Description......82
Diagnosis using the Service display unit (serial no. 3031)......83
Engine speed, measuring method with information display unit (serial no. 3030)......84
Engine speed, measuring method......85
Troubleshooting......87
21 - ENGINE......88
Compression check, engine at operating temperature......88
Crankshaft, changing front oil seal (in machine)......90
Crankshaft, changing rear oil seal (engine removed from machine)......95
Engine and transmission, mounting......100
Engine and transmission, removing......107
Engine, mounting......117
Engine, removing......122
Flywheel housing (rear engine transmission) and power take-off......129
Flywheel housing with power take-off, removing and mounting (engine removed from machine)......132
General......135
Specifications TD121 G (serial no. 1051)-[4955]......136
Specifications TD122 GA (serial no. 1052)......137
Tightening torques ......138
Tightening torques-......139
Tightening torques......140
Valves, adjusting......142
Weights......144
22 - LUBRICATING SYSTEM......145
Capacities......145
Description......146
Specifications TD121 G (serial no. 1051)......149
Specifications TD122 GA (serial no. 1052)......150
23 - FUEL SYSTEM......151
Capacities......151
Description......152
Flange discs on pump shaft, checking......154
Fuel feed pressure, checking......156
Fuel feed pump (serial no. 1052)......158
Fuel feed pump (serial no. 1051)......159
Fuel injection angle (injection timing), checking and adjusting......160
Fuel injection pump (serial no. 1052)......164
Fuel injection pump (serial no. 1051)......165
Fuel system, bleeding air......166
Injectors (serial no. 1052)......168
Injectors (serial no. 1051)......169
Injectors, changing......170
Low and High idle speeds, checking and adjusting with service display unit......174
Low and High idle, checking and adjusting......177
Stalling speed, checking with Service display unit......180
Stalling speed, checking......182
25 - INLET & EXHAUST SYSTEM......184
Cold start device......184
General ......185
26 - COOLING SYSTEM......186
Brake oil pump, piston rings, changing (serial no. 1827)......186
Capacities......192
Coolant filter, changing......193
Coolant pump removed, reconditioning (serial no. 2199)......195
Coolant pump removed, reconditioning (serial no. 2198)......203
Coolant pump, changing......210
Coolant, changing......212
Cooling fan drive, description......214
Cooling fan, troubleshooting of hydraulic system......217
Cooling system, principle illustration (earlier version)......220
Cooling system, principle illustration (later version)......222
General-......223
General......224
Hydraulic motor and hydraulic pump for fan, checking and adjusting......225
Hydraulic motor for fan, or hydraulic pump for fan, checking internal leakage......227
Hydraulic motor for fan, reconditioning......229
Hydraulic motor for fan......237
Radiator, adjusting......241
Radiator, changing......243
Thermostat (serial no. 1052)......246
Thermostat (serial no. 1051)......247
Thermostat valve, checking function......248
Thermostat valve, description......250
Thermostat valve, reconditioning (removed)......252
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS......254
30 - GENERAL......255
Circuit 1 (serial no. 10813030)......255
Circuit 1 (serial no. 3031)......259
Circuit 1 (serial no. 1081)......263
Circuit 10 (serial no. 3031)......266
Circuit 11 (spare) (serial no. 3031)......271
Circuit 2 (serial no. 10813030)......273
Circuit 2 (serial no. 3031)......279
Circuit 2 (serial no. 1081)......283
Circuit 3 (serial no. 10813030)......287
Circuit 3 (serial no. 3031)......292
Circuit 3 (serial no. 1081)......296
Circuit 4 (serial no. 10813030)......299
Circuit 4 (serial no. 3031)......305
Circuit 4 (serial no. 1081)......309
Circuit 5 (serial no. 10813030)......313
Circuit 5 (serial no. 3031)......318
Circuit 5 (serial no. 1081)......323
Circuit 6 (serial no. 10813030)......327
Circuit 6 (serial no. 3031)......331
Circuit 6 (serial no. 1081)......336
Circuit 7 (serial no. 10813030)......339
Circuit 7 (serial no. 3031)......343
Circuit 7 (serial no. 1081)......347
Circuit 8 (serial no. 3031)......350
Circuit 9 (serial no. 3031)......354
Codes used in wiring diagrams......358
Description......371
Electrical symbols......373
Explanations of wiring diagrams......378
General......380
31 - BATTERY......381
General......381
32 - ALTERNATOR; CHARGE REGULATOR......382
Alternator, changing......382
Charging, checking in machine......384
General......386
33 - STARTING SYSTEM......387
General......387
Starter motor, changing......388
35 - LIGHTING......389
General......389
Headlights, alignment......390
Headlights, changing bulb (serial no. 1689)......391
Headlights, changing bulb (serial no. 1688)......392
37 - CABLE; FUSE; RELAY......393
Electrical distribution box in the cab......393
Fuses......394
Left electrical distribution box......395
Other fuses and relays (serial no. 3031)......398
Other fuses and relays (serial no. 3030)......400
Right electrical distribution box (serial no. 3031)......402
Right electrical distribution box (serial no. 3030)......404
38 - INSTRUMENT; SENSOR; WARNING & INFORMATION SYSTEM......406
Combination instrument......406
Contronic service display unit......408
Contronics information display unit (serial no. 3031)......410
Diagnosis using the Contronics information display unit (serial no. 3030)......412
Diagnosis using the service display unit......421
Information display unit, summary......425
Information on the information display unit......426
Information on the service display unit......432
Operator information......445
Other operating controls (serial no. 3031)......446
Other operating controls (serial no. 3030)......448
Right instrument panel (serial no. 3031)......450
Right instrument panel (serial no. 3030)......452
Service display unit, summary......454
4 - POWER TRANSMISSION......456
40 - GENERAL......457
Description......457
Troubleshooting (serial no. 3031)-[5200]......459
Troubleshooting (serial no. 3030)......460
41 - CLUTCH; TORQUE CONVERTER......461
General......461
Tightening torques......462
Weights......463
42 - TRANSMISSION; HYDRAULIC CONTROL......464
Checking modulating valve, retarder and Lock-up (serial no. 3030)......464
Checking modulating valves, retarder and Lock-up (serial no. 3031)......465
Checking pressure in clutches and brakes (serial no. 3031)......466
Checking pressure in clutches and brakes (serial no. 3030)......469
Checking resistance in SE3 and SE4......472
Checking resistance in connector EH......474
Checking resistance in pin connector......476
Connector EH......477
Control system for automatic gearshifting in transmission, changing......480
Diagnosis using the Contronic information display unit (serial no. 3030)......484
Diagnosis using the Contronic service display unit (serial no. 3031 )......496
Missing signal from both engine speed sensor (SE3) and speed sensor (SE4)......508
Missing signal from engine speed sensor (SE3)......509
Other causes of malfunction or failure......510
Pin numbering in EA (serial no. 3031)......512
Pin numbering in EA (serial no. 3030)......513
Pin numbering in EB (serial no. 3031)......514
Pin numbering in EB (serial no. 3030)......515
Pressure regulator for retarder, checking and adjusting (serial no. 3031)......516
Pressure regulator for retarder, checking and adjusting (serial no. 3030)......518
Retarder temperature sensor (SE13), checking resistance......520
Retarder valve, changing seal......521
Table for oil pressure, transmission......522
Transmission output shaft, changing seal......523
Transmission, mounting downward......525
Transmission, mounting upward through door opening......530
Transmission, removing downward......534
Transmission, removing upward through door opening......542
Weights......550
43 - GEARBOX......551
Capacities ......551
Capacities-......552
Checking main, torque converter and lubrication oil pressure......553
Clutches, brakes and solenoids......557
Components and description (serial no. 3031)......560
Components and description (serial no. 3030)......562
Dropbox 6x6, drawing......564
Dropbox FL752, drawing......566
Dropbox, cable harness and sensors SE54 and SE55......568
Dropbox, front output shaft, changing seal......571
Dropbox, input shaft, changing seal......573
Dropbox, mounting......575
Dropbox, rear output shaft, changing seal......579
Dropbox, removing......581
Final drive and differential lock for drive axle AH 63 H, drawing......585
Gearshifting control system (serial no. 3031)......588
Gearshifting control system (serial no. 3030)......589
General-......591
General......592
Hub reduction for drive axle, drawing......593
Hydraulic diagram, transmission PT1662......595
Longitudinal differential lock, checking and adjusting, from underneath......599
Sensors SE54 and SE55, adjusting......605
Sensors SE54 and SE55, checking with information panel......608
Tightening torques-[3356]......610
Tightening torques......611
Transmission PT1662, drawing......612
Weights-......614
Weights......615
45 - PROPELLER SHAFT......616
Dropbox, front output shaft, changing......616
Dropbox, input shaft, changing......618
Intermediate propeller shaft (frame joint) and_or bearing, changing......620
Propeller shaft for front bogie axle, changing......630
Propeller shaft for rear bogie axle, changing......632
Propeller shaft in steering joint, changing......634
Tightening torques......635
Transverse differential, checking and adjusting (all axles)......636
46 - FRONT AXLE; REAR AXLE......640
Capacities-[1523]......640
Capacities-[1644]......641
Capacities-[1949]......642
Dog-clutch for six-wheel drive (6x6), checking and adjusting......643
Front bogie axle, output shaft, changing seals and bearings......646
General-[1457]......651
General-[1618]......652
General-[1854]......653
General-[2110]......654
Hub reduction, changing seals......655