Volvo L35G Compact Wheel Loader Workshop Repair Service Manual PDF Download - MVLVCONL35G.zip
A full workshop repair and service manual, complete with electrical wiring diagrams, for the Volvo L35G Compact Wheel Loaders — containing every technical detail needed to service, troubleshoot, fix, and rebuild your machine the way professional technicians do.
The Volvo Construction L35G Compact Wheel Loaders service and repair manual covers:
* 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 L35G Compact Wheel Loaders Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 1,412 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - Foreword................2
0 - GENERAL................3
03 - SPECIFICATIONS................4
Measurement conversion tables................5
Volvo standard tightening torques................10
07 - STANDARD TIME................12
Operation numbers for additional work................13
08 - TOOL................15
E-tool Cab support................16
Infrared Thermometer................17
1 - STANDARD PARTS; SERVICE................21
16 - LUBRICANT; FUEL; OTHER FLUID................22
Recommended lubricants_{08-51-10}................23
Recommended lubricants_{08-50-37}................26
Coolant with freezing and corrosion protection................29
Fuel; recommendation................30
This statement is only valid for Volvo branded engines._{08-46-53}................31
Engine oil................34
17 - SERVICE................35
Service................37
Service and maintenance................38
Work on the machine's electrical system................40
Cleanliness; braking and hydraulic system................41
Charging batteries................42
Electric welding................43
Tech Tool; operations ................44
Service position 2_{08-41-43}................45
Service position 1_{08-41-15}................48
Maintenance service; every 10 hours................51
Maintenance service; every 50 hours................52
Maintenance service; every 500 hours................53
Maintenance service; every 1000 hours................54
Maintenance service; every 1500 hours................56
Maintenance service; every 2000 hours................58
Maintenance service; every 3000 hours................60
Maintenance service; every 6000 hours................62
Test running and checking................63
Leakage; checking................64
Lubrication................65
Engine belt tension; checking................67
Crankcase ventilation separator element; replacing................70
Valves; adjusting ................72
Engine oil level; checking................76
Engine oil and filter; changing................77
Water separator; checking................79
Fuel filters; replacing................80
Fuel tank breather filter; replacing................82
Fuel injectors; checking................83
Diesel particulate filter; checking and cleaning................84
Turbocharger; checking................91
Engine air cleaner primary filter; replacing................92
Engine air cleaner secondary filter; replacing................94
Coolant level; checking................95
Coolant; changing................97
Coolant freezing point; checking................100
Radiator and hydraulic oil cooler; cleaning................102
EGR system; checking................103
MATRIS and Tech Tool; reading................112
Battery; checking................113
Axle oil; changing................114
Brake fluid level; checking................117
Service brake pads; checking................118
Steering pressure; checking ................119
Steering cylinders; locking of pivot pins; checking................122
Tyre wear and air pressure; checking................123
Wheel nuts torque; checking................124
Cab main filter; replacing................125
Hydraulic oil level; checking................127
Hydraulic oil; changing................129
Hydraulic oil filters; replacing................131
Hydraulic tank sediment; draining................133
Hydraulic pressure; checking................134
Towing a disabled machine................137
19 - GENERAL................139
Safety concerns everybody!................140
CE-marking; EMC-directive................142
Safety when handling the machine................146
Safety rules when servicing................150
Service position 2................153
Service position 1................156
Loader boom; safety strut................159
Working under raised boom................162
Fire prevention measures................164
Some simple rules regarding tyre handling................167
Safety when lifting and supporting complete machine................169
Safety when working with batteries................171
Starting with booster batteries................174
Safety when handling oils and fuel................176
Safety when handling accumulators................177
Safety when working on hydraulic systems................178
Checklist after a fire or heat exposure................180
Health hazards with paint; plastics and rubber................181
Environmental handling for the future................183
Waste handling................185
Environmentally safe handling................186
Environmentally hazardous fluids................188
Safety when working with refrigerant................189
Working in environmentally contaminated areas................192
Decontamination................193
2 - ENGINE WITH MOUNTING AND EQUIPMENT................195
20 - GENERAL................196
Engine; description_{05-11-15}................197
Engine; description_{05-11-13}................201
Engine; description_{05-10-43}................204
E-ECU MID 128 pre-programmed; replacing................208
E-ECU MID 128 non-programmed; replacing................210
Tech Tool; operations-[5104]................212
Component locations_{04-50-35}................214
Engine; capacity_{04-08-26}................217
Engine; capacity_{04-08-05}................218
Engine; weights_{04-07-13}................219
Engine; weights_{04-06-51}................220
Electric components location_{01-52-07}................221
Electric components location_{01-51-43}................224
21 - ENGINE................227
Engine; specifications_{01-49-23}................228
Engine; specifications_{01-49-02}................229
Engine; removing................231
Engine; installing................239
Cylinder compression; testing................246
Cylinder head gasket; replacing................248
Valve system specifications................265
Valves; adjusting................266
Valve cover; removing................270
Valve cover; installing................273
22 - LUBRICATING SYSTEM................276
Lubricating system; description_{10-27-08}................277
Lubricating system; description_{10-26-43}................281
Lubrication system; specifications................285
Lubrication system; tightening torques................286
Oil pressure relief valve; replacing................287
Lubrication oil pressure; checking................289
Oil cooler; replacing................291
23 - FUEL SYSTEM................293
Fuel system; description_{09-51-42}................294
Fuel system; description_{09-51-02}................299
Fuel system; specifications................305
Fuel tank; capacities................306
Fuel system; tightening torques................307
Fuel pump unit; replacing ................308
Fuel tank; replacing................317
Fuel tank level sensor; replacing................320
Injectors; tightening torques................322
Injectors; replacing................323
Fuel pump unit; replacing................326
25 - INLET & EXHAUST SYSTEM................335
Inlet and exhaust system; description................336
Inlet and exhaust system; component location................340
Exhaust Aftertreatment System; description_{09-41-07}................342
Exhaust Aftertreatment System; description_{09-40-37}................346
Exhaust Aftertreatment System; description_{09-40-04}................350
Exhaust Aftertreatment System; component location_{10-36-12}................354
Exhaust Aftertreatment System; component location_{10-35-48}................356
Regeneration process; description................358
DPF (Diesel particulate filter); checking and cleaning................360
Inlet throttle; replacing................367
Charge air cooler; replacing................371
26 - COOLING SYSTEM................374
Cooling system; description................375
Cooling system; capacity................378
Cooling package; removing................379
Cooling package; installing................390
Coolant pump; replacing................399
Thermostat; replacing................401
Cooling fan rpm; specifications................403
Cooling fan; description_{10-26-32}................405
Maximum fan speed; checking................407
Fan motor; removing_{10-24-50}................411
Fan motor; removing_{10-24-20}................418
Fan motor; installing_{07-40-10}................424
Fan motor; installing_{07-39-44}................430
29 - MISCELLANEOUS................436
Exhaust Gas Recirculation (EGR); description_{07-38-58}................437
Exhaust Gas Recirculation (EGR); description_{07-38-24}................441
3 - ELECTRICAL; WARNING; INFORMATION; INSTRUMENTS................445
30 - GENERAL................446
Electrical system; work instructions................450
Electrical system; description................453
Electronic control system; description................455
Communication with data buses................458
Electrical system; specifications................460
Tech Tool; operations ................461
Automatic engine shut down; description................463
Software parameters; description................465
Power derating_{07-32-41}................472
Power derating_{07-32-19}................474
DPF regeneration control_{07-31-40}................475
DPF regeneration control_{07-31-15}................482
General fault diagnosis information................486
Troubleshooting strategy................488
Collection of basic data................490
Error codes; build-up................492
SAE error codes; translation to error messages; general................495
Conditions when checking................497
Lead and connector checks................500
Troubleshooting tools................504
Special tools for troubleshooting................505
Tech Tool; operations................506
AL3201; description and measuring................507
FX1005; description and measuring_{07-22-20}................509
FX1005; description and measuring_{07-21-42}................511
FX1052; description and measuring................513
FX1053; description and measuring................516
FX1054; description and measuring................518
MA2301-MA2304; description and measuring................520
MA2310; description and measuring................522
MA2602; description and measuring_{07-13-57}................524
MA2602; description and measuring_{07-13-07}................526
MA4220; description and measuring_{07-12-07}................528
MA4220; description and measuring_{07-11-17}................530
MA4221; description and measuring_{07-10-18}................532
MA4221; description and measuring_{07-09-29}................534
MA4234; description and measuring................536
MA4235; description and measuring_{07-07-17}................538
MA4235; description and measuring_{07-06-37}................540
MA4605; description and measuring_{07-05-42}................542
MA4605; description and measuring_{07-04-59}................544
MA4710_MA4711; description and measuring_{07-04-06}................546
MA4710_MA4711; description and measuring_{07-03-26}................548
MA4720; description and measuring_{07-02-27}................550
MA4720; description and measuring_{07-01-36}................552
MA9172_MA9174; description and measuring_{07-00-37}................554
MA9173; description and measuring_{06-59-45}................556
PWM2602; description and measuring_{06-58-30}................558
PWM2602; description and measuring_{06-58-00}................560
RE01; description and measuring................562
RE04; description and measuring................564
RE05; description and measuring_{06-55-18}................566
RE05; description and measuring_{06-54-34}................568
RE2501; description and measuring_{06-53-28}................570
RE2501; description and measuring_{06-52-51}................572
RE3301; description and measuring................574
RE3504; description and measuring_{06-51-02}................576
RE3504; description and measuring_{06-50-18}................578
RE3505. description and measuring................580
RE8701; description and measuring................582
SAE J1939_CAN1 Control link; description and measuring_{06-46-33}................584
SAE J1939_CAN1 Control link; description and measuring_{06-46-00}................586
SAE J1939_CAN2 control link; description and measuring_{06-45-12}................588
SAE J1939_CAN2 control link; description and measuring_{06-44-31}................591
SE2206; description and measuring................594
SE2303; description and measuring_{06-42-26}................596
SE2303; description and measuring_{06-41-47}................599
SE2306; description and measuring................601
SE2309; description and measuring................603
SE2502; description and measuring_{06-39-00}................605
SE2502; description and measuring_{06-38-28}................607
SE2507; description and measuring................609
SE2508; description and measuring................611
SE2510; description and measuring_{06-35-59}................613
SE2510; description and measuring_{06-35-24}................615
SE2519; description and measuring_{06-34-36}................617
SE2519; description and measuring_{06-34-07}................619
SE2521; description and measuring_{06-33-25}................621
SE2521; description and measuring_{06-32-50}................623
SE2522; description and measuring_{06-31-56}................625
SE2522; description and measuring_{06-31-20}................627
SE2606; description and measuring................629
SE2702; description and measuring_{06-29-33}................631
SE2702; description and measuring_{06-28-53}................633
SE2709; description and measuring................635
SE2710; description and measuring................637
SE4307; description and measuring................639
SE9105; description and measuring................641
SE9106; description and measuring................643
SW2506; description and measuring_{06-22-36}................645
SW2506; description and measuring_{06-22-11}................647
SW4205; description and measuring................649
Component descriptions................651
Limp Home................654
31 - BATTERY................656
Battery; description................657
Battery; specifications................658
Battery; charging................659
32 - ALTERNATOR; CHARGE REGULATOR................660
Alternator; replacing incl function checking................661
Alternator; testing................663
33 - STARTING SYSTEM................665
Booting sequence................666
Preheating; specifications................667
Glow plug; removing................668
Glow plug; installing................670
Glow plugs; testing................672
36 - OTHER ELECTRICAL EQUIPMENT................673