Volvo A35E A35E FS Articulated Hauler Workshop Repair Service Manual PDF - MVOLCONA35E.zip
Full workshop service manual, complete with electrical wiring diagrams, covering Volvo A35E and A35E FS Articulated Haulers. It contains every technical detail needed to service, troubleshoot, repair, and overhaul these machines at a professional mechanic's level.
This Volvo Construction Equipment workshop service and repair manual for the A35E and A35E FS Articulated Haulers 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.
Articulated Haulers A35E Volvo, A35E FS Volvo Service Repair Manual.pdf
PRODUCT DETAILS:
Total Pages: 3,002 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
0 - GENERAL...2
00 - DESCRIPTION; COMPLETE MACHINE...3
Description ...4
Product identification plates...6
Information and warning decals...8
03 - SPECIFICATIONS...11
Tightening torques...12
Capacities...23
Machine dimensions...24
Weights...28
Rocker arm shaft; tightening torques_{39-48}...29
Rocker arm shaft; tightening torques_{39-33}...30
Coolant with anti-freeze and corrosion protection; recommendation...32
Tightening torques; valve cover ...34
Power take-off; tightening torque ...35
Tyre equipment and recommended tyre pressures...37
Lubrication system; specifications...39
05 - TRANSPOET INSTRUCTION; STORAGE INSTRUCTION; OPERATIONG INSTRUCTION...40
Recovering and towing...41
Lifting machine...43
07 - STANDARD TIME...46
Operation numbers for additional work...47
08 - TOOL...49
E-1763...50
E-2000...52
E-2500...54
E-2501...56
E-2502...58
E-2503...60
E-2506...61
E-2507...62
E-2511...63
E-2518...65
E-2519...67
E-2520...69
E-2524...71
E-2538...78
E-2548...80
Infrared Thermometer...82
88830051 User Instruction...86
09 - MISCELLANEOUS...96
Troubleshooting; Heneral...97
Troubleshooting strategy ...98
Troubleshooting; assistant devices...101
Collection of basic data...102
VCADS Pro service tool; general...105
VCADS Pro; Test...107
VCADS Pro; Error codes...109
VCADS Pro; Calibrating...111
VCADS Pro; Programming...113
VCADS Pro tests...116
Basic checks...120
Engine; basic check...122
Electrical system; basic check ...126
Power transmission; basic check...130
Brake system; basic check...132
Parking brake; basic check...135
Steering and hydraulics; basic check...137
1 - STANDARD PARTS; SERVICE...139
11 - STANDARD PARTS...140
Service ...141
16 - LUBRICANT; FUEL; OTHER FLUID...142
Recommended lubricants...143
Alternative fuels...145
17 - SERVICE...148
Service...152
Safety when servicing...153
Arrival Inspection; according to Inspection Programme...155
Delivery Inspection; according to Inspection Programme...156
Maintenance of Stored Machines; according to Inspection Programme...157
Warranty inspection...158
Warranty inspection 100 hours...159
Warranty inspection 1000 hours...161
Maintenance service; daily...163
Maintenance service; every 50 hours...164
Maintenance service; every 250 hours...165
Maintenance service; every 500 hours...166
Maintenance service; every 1000 hours...168
Maintenance service; every 2000 hours...170
Maintenance service; every 4000 hours...173
Maintenance service; every 6000 hours...176
Maintenance service; every 12000 hours_{15-51}...179
Maintenance service; every 12000 hours_{15-35}...182
Condition test and maintenance program...185
Test-run and check...187
MATRIS; reading; export reading...188
VCADS Pro; logged errors; read off...189
Alternative exit; checking...190
Fuel; coolant and oil leakage; check...192
Brake pipes and hoses; check...193
Coolant's freezing point; check...194
Belts and belt tension; check; replace when needed...195
Battery; charging state; electrolyte level; cables and connections; especially connections at starter motor; check...196
Engine mounts_dropbox mounts_propeller shafts; bolted joints and flange mounts; check torques...198
Axle mounts; bolted joints; tourque; check...201
Tyres; wear and air pressure; checking...202
Cab; air pre-cleaner filter; clean_change...203
Cab; prefilter; replace...205
Cab main filter; replacing...206
Cab; asbestos filter; replacing...207
Engine; air cleaner; cover; clean...208
Engine; air pre-cleaner; check_clean...209
Engine; air cleaner; main filter; replace. EON (option) only replace when indicated...211
Engine; air cleaner; secondary filter; replace. EON (option) only when indicated...212
Fuel system; extra fuel pre-filter; drain...214
Fuel system; extra fuel pre-filter; change...216
Fuel filters; primary and secondary filter; replace...218
Oil-bath air cleaner's reservoir (optional equipment); oil; check...220
Oil-bath air cleaner's reservoir (optional equipment); clean; and oil; change...222
Oil-bath air cleaner's reservoir (optional equipment); filter insert; clean...224
Engine; oil and filter; change...225
Power take-off suction strainer; cleaning...227
Fuel tank; sediment; drain. Shorter interval as needed...229
Transmission; oil; main oil filter and lubrication oil filter; replace...231
Dropbox; oil; replace...234
Frame joint oil; check...236
Frame joint oil; change...237
Radiator; clean (from fan side with compressed air)...239
Condenser; clean (with compressed air) (optional equipment)...240
Air drier; drier cartridge; replace...241
Cooling fan; return oil filter; replacing...242
Brake system; pressure oil filter; replace...243
Drive axles; oil; change...245
Brake cooling oil; level; check...248
Brake cooling oil tank; oil; change...249
Brake cooling oil tank; return oil filter; replace and magnetic rods; clean...251
Hydraulic oil tank; oil; replace if system is filled with mineral oil or Volvo Biodegradable hydraulic oil 46. If system is filled with other biologically degradable hydraulic oil; replace every 2000 hour...253
Hydraulic oil tank; return oil filter; replace; and magnetic rods; clean...255
Fuel tank; hydraulic oil tank; brake cooling oil tank; breather filter; replace...257
Drive axles; transmission; dropbox and frame joint; breather filter; replace...259
Service brake; brake disc wear; check...262
Parking brake pads; check...265
Steering cylinder bearings; clearance; check...266
Load body; rubber cushions; clearance; check...268
Front frame; rear section; cracks; checking...269
Steering joint bearings; first check of steering joint bearings after 6000 hours. Thereafter every 2000 hours...270
Frame joint bearings; clearance; check...272
Valve clearance and IEGR; double rocker arms; check_adjust...274
Accumulator; checking...275
FS-cylinder; rubber bearings; check; after first 4000 hours; then after every 1000 hours...276
Load body; exhaust heated; check_clean_grease...277
Automatic central lubrication; filter; cleaning_replacing...280
Dropbox quick drain valve; replacing_{50-57}...282
Dropbox quick drain valve; replacing_{49-27}...285
Lubrication; see lubrication chart...287
Service journal (included in Operator's manual); fill in...288
Coolant; changing ...289
Dump body alternative; lowering-45...294
Dump body alternative; lowering ...296
Parking brake; manually releasing ...298
Transporting the machine...300
19 - GENERAL...302
Cleanliness; brake and hydraulic systems...304
Refrigerant for air conditioning...305
CE-marking; EMC-directive...306
Safety concerns everybody!...310
Safety when handling the machine...314
Service position 3_{29-05}...318
Service position 2_{26-18}...324
Checking function...328
Safety when lifting and supporting the machine...330
Safety when using lifting equipment...332
Rules when handling tyres...334
Safety when working with batteries...337
Starting with booster batteries...339
Safety when handling oils and fuel...340
Safety when working on pressurized systems...341
Safety when working on hydraulic systems...343
Safety when handling accumulators_{01-04}...345
Safety when handling accumulators_{59-56}...346
Safety when working on the machine's electrical system...347
Safety during electric welding...348
Fire prevention measures...349
Checklist after a fire or heat exposure...352
Health hazards with paint; plastics and rubber...355
Environment...358
Environmental handling for the future...360
Waste handling...362
Environmentally safe handling...366
Environmentally hazardous fluids...368
Safety when working with air conditioning refrigerant...371
Working in environmentally contaminated areas...374
Decontamination...377
2 - ENGINE WITH MOUNTING AND EQUIPMENT...381
20 - GENERAL...382
Engine; description...383
Engine Protection...385
Tightening torques; engine mounts...387
Engine; capacities...389
Engine; identification...390
E-ECU MID 128 pre-programmed; replacing...392
E-ECU MID 128 non-programmed; replacing...394
21 - ENGINE...397
Engine; general specifications...399
Cylinder compression; PC test...401
Engine and transmission; removing...402
Engine and transmission; installing...422
Engine rotation speed sensor; replacing...442
Engine rotation speed sensor (camshaft); replacing...449
Camshaft and flywheel signals; checking with Tech Tool and oscilloscope...455
Cylinder compression; testing...461
Tightening torques; valve cover...470
Tightening torque; cylinder head...471
Cylinder head; description...472
Cylinder block; description...474
Oil trap; description...477
Cylinder liner; description...480
Pistons; description...482
Valve system; specification...483
Valve mechanism; double rocker arm...484
Rocker arm shaft; tightening torques_{33-58}...485
Rocker arm shaft; tightening torques_{33-05}...486
Valve mechanism; description...488
Adjusting; general...490
Internal Exhaust Gas Recirculation (IEGR); description...492
Valves; adjusting...498
Valve cover; removing...505
Valve cover; installing...508
Engine transmission; specification...513
Engine timing gear; description...516
Camshaft; description...518
Camshaft setting; checking...519
Camshaft; replacing...529
Timing gear case new gasket; installing...548
Crank mechanism; description...559
Flywheel; tightening torques...561
Crankshaft rear oil seal; replacing...562
Oil sump; tightening torque...569
Oil level sensor; replacing...571
Oil sump gasket; replacing...578
Engine mount rubber cushion; replacing...585
Engine mounting rear; changing...589
22 - LUBRICATING SYSTEM...593
Lubrication system; description_{11-50}...594
Lubrication system; description_{10-57}...595
Lubrication system; specifications...596
Lubrication oil pressure; checking with pressure gauge...597
Oil cooler; tightening torques ...599
Oil cooler; replacing...602
23 - FUEL SYSTEM...606
Fuel system; tightening torques...607
Fuel system; description...608
Fuel flow; description...611
Air in fuel system; checking...614
Carbon dioxide in fuel system; checking...618
Fuel feed pump; specifications_{52-46}...624
Fuel feed pump; specifications_{52-04}...625
Fuel feed pump; description...626
Feed pump pressure; checking...629
Fuel filter housing; description...631
Fuel pump; inspecting...634
Fuel pump (valves); inspecting...639
Fuel system; bleeding...641
Feed pressure; PC test...643
Fuel tank; volume...644
Stall speed; checking...645
Unit injectors; specifications...648
Unit injectors; description...649
Unit injector pretension; adjusting...652
Unit injector; replacing...654
Injector shut off; manual...663
Overflow valve; checking...664
Injector sleeves; replacing...667
25 - INLET & EXHAUST SYSTEM...675
Air intake and filter...676
Charge-air cooling...677
Exhaust pressure governor...678
Turbocharger; description...679
Turbocharger; specifications...682
Turbocharger; inspecting...683
Turbocharger; replacing...686
Air cleaner; preheating coil; specifications...691
Air cleaner; description...692
Preheating coil; replacing...693
Intercooler; specifications...696
Intercooler; description...697
Charge air cooler; replacing...699
Fan pump; Removing...707
Fan pump; Installing...708
Cooling fan motor; charge air cooler; checking_adjusting low rpm...709
Cooling fan motor; charge air cooler; checking_adjusting high rpm...713
Hydraulic cooling fan control; PC test...717
26 - COOLING SYSTEM...718
Cooling system; tightening torques...719