Volvo A35C Articulated Dump Truck Repair Manual

Table of Content A35C Service Information

GENERAL
DESCRIPTION, COMPLETE MACHINE
General
Product identification plates
STANDARD TIME
TOOL
Drawings of E-tools that can be made in your own workshop
STANDARD PARTS, SERVICE
LUBRICANT; FUEL; OTHER FLUID
SERVICE
Maintenance
Electric welding
Emergency measures
ENGINE WITH MOUNTING AND EQUIPMENT
General, engine installation and its function
Specifications, general (serial no. 5201 Ţ€“, US 60301Ţ€“)
Specifications, general (serial no. Ţ€“5200, US Ţ€“60300)
ENGINE
General, common info about 211 – 218
Compression check, engine at operating temperature
Specifications, capacities
Valve mechanism
Specifications, general
LUBRICATING SYSTEM
General, common info about 221 – 224
Oil filter; filter housing
Oil cooler
Specifications, weights
FUEL SYSTEM
General (common info about 233 – 238)
Low emission engines
Fuel pump; filter; strainer
Fuel system, bleeding air
Fuel tank; fuel filling pump
Injection pump; regulator; pump companion
Injection timing, checking and adjusting
Low and high idle speed, checking and adjusting with service display unit
Stall speed, checking with service display unit
Injector; delivery pipe
Control system; control unit (for ex. injection timming adjuster)
Automatic timing adjuster (alpha adjuster)
Automatic timing adjuster, checking
INLET SYSTEM; EXHAUST SYSTEM
Silencer; exhaust pipe
Exhaust brake
Turbo charger
Air cleaner with connections; air pre-heater
COOLING SYSTEM
General, common info about 261 – 269
Radiator, mounting and connections included
Radiator, changing
Coolant pump; thermostat
Coolant pump, removed, reconditioning
Fan; fan shroud; fan coupling
Fan motor, adjusting speed
Hydraulic motor and hydraulic pump for fan,checking and adjusting
ELEC. SYSTEM; WARNING SYSTEM; INFORMATION SYSTEM; INSTRUMENTS
Comprehensive info, electrical system
Special instructions for servicing the electrical system
BATTERY; ENERGY STORAGE SYSTEM; MOUNTING PARTS
Battery
ALTERNATOR; CHARGING; ELECTRIC MOTOR; ELECTRIC DRIVES
General, common info about 321 – 322
Alternator inclusive drive
Alternator, changing
STARTING SYSTEM
Starter motor inclusive solenoid
Starter motor, changing
LIGHTING
General, common info about 351 – 356
Lighting, front, including parking light and day running light
Headlights, changing light bulb
CABLE; FUSE; RELAY
General, common info about 371 – 379
Circuit 1 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 1 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 2 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 2 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 3 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 3 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 4 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 4 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 5 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 5 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 5 contŢ€™d. (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 5 contŢ€™d. (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 6 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 6 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 6 contŢ€™d. (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 6 contŢ€™d. (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 7 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 7 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 8 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 8 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 9 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 9 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 10 (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 10 (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 11, spare (serial no. Ţ€“5200, US Ţ€“60300)
Circuit 11, spare (serial no. 5201Ţ€“, US 60301Ţ€“)
Circuit 12 (serial no. 5201Ţ€“, US 60301Ţ€“)
Cable; battery disconnector
Connectors, cables (serial no. 5201Ţ€“, US 60301Ţ€“)
Connectors, cables (serial no. Ţ€“5200, US Ţ€“60300)
Electrical distribution box; fuse box; junction box
Left electrical distribution box
Right electrical distribution box (serial no. Ţ€“5200, US Ţ€“60300)
Right electrical distribution box (serial no. 5201Ţ€“, US 60301Ţ€“)
INSTRUMENT; SENSOR; WARNING AND INFORMATION SYSTEM
General, common info about 383 – 387
Combination instrument (serial no. Ţ€“4915, US Ţ€“60080)
Other instruments and operating controls (serial no. 5201Ţ€“, US 60301Ţ€“)
Other operating controls (serial no. Ţ€“5200,
Right instrument panel (serial no. Ţ€“5200, US Ţ€“60300)
(serial no. 5201Ţ€“, US 60301Ţ€“)
Speedometer, electric, calibrating
Speedometer, electric, changing (serial no. 4916Ţ€“5591, US 60081Ţ€“60468)
Sender, monitoring system
Sensor for retarder temperature (SE13), measuring resistance
Warning/information unit, display unit
Contronic Information display unit
Information display unit, summary
Information display unit, displays
POWER TRANSMISSION
General, common info about 410 – 436
Checking main, torque converter and lubrication oil pressure
CLUTCH; TORQUE CONVERTER
Hydrodynamic coupling, torque converter
TRANSMISSION, HYDRAULIC CONTROL
Transmission, hydraulic control
Missing signal from both engine speed sensor (SE3) and speed sensor (SE4)
Missing signal from engine speed sensor (SE3)
Retarder valve, changing seal
Transmission retarder valve, adjusting airł pressure
Transmission, checking resistance of solenoids
Transmission, mounting downward through door opening
Transmission, removing upward
Turbine speed sensor, changing
GEARBOX,
Distributing gearbox
Checking and adjusting longitudinal differential lock Ţ€“ from underneath
Dropbox, changing seal for rear output shaft
Dropbox, changing seal for front output shaft
Sensors for high and low range, adjusting
PROPELLER SHAFT
General, common info about 451 – 453
Propeller shaft, complete
Propeller shaft between transmission and dropbox, changing
Propeller shaft for rear bogie axle, changing
Propeller shaft, front output shaft on dropbox, changingł
Propeller shaft for front bogie axle, changing
FRONT AXLE; REAR AXLE
General, common info about 461 – 468
Dog clutch 6×6, checking and adjusting
Front axle
Rear axle 1
Rear axle 2
Differential lock, with control
Transverse differential lock, adjusting engagement (per axle)
MISCELLANEOUS
General, common info about 491 – 492
Transmission, hydraulic diagram
BRAKE
Comprehensive info about brakes
Specifications, tightening torques
WHEEL BRAKE
General, common info about 511 – 519
Brake pads for service brake, changing
Rear wheel brake, axle 1, dry brake
Brake caliper, reconditioning
HYDRAULIC BRAKE SYSTEM
General, common info about 520 – 522
Brake system, bleeding and filling oil
Brake system, changing brake oil and pressure filter (serial no. Ţ€“5200, US Ţ€“60300)
pressure filter (serial no. 5201Ţ€“, US 60301Ţ€“)
Brake system, bleeding and filling oil (serial no. Ţ€“5200, US Ţ€“60300)
Brake system, checking function
Brake pads for service brake, checking
Brake valve
Foot brake valve, changing
Foot brake valve, reconditioning (removed)
Unloading valve and non-return valve block, removing and mounting
Unloading valve, functional description
Brake accumulator; hydraulic pump
Accumulator, checking
PARKING BRAKE
General, common info about 551 – 554
Parking brake caliper, removed, reconditioning
Parking brake valve, reconditioning (removed)
Parking brake, changing brake caliper
Spring brake cylinder, changing
Spring brake cylinder, removed, reconditioning
Propeller shaft brake
COMPRESSED-AIR BRAKE
General, common info about 561 – 565
Compressor; regulator; anti-freez unit
General repair instructions, compressor
Compressed-air tank, with mounting
Valves, compressed-air
General, common info about 591 – 594
Compressed air diagram (serial no. Ţ€“5200, US Ţ€“60300)
Compressed air diagram (serial no. 5201Ţ€“, USł 60301Ţ€“)
Compressed air system, position list (serialł no. 5201Ţ€“, US 60301Ţ€“)
Compressed air system, position list (serialł no. Ţ€“5200, US Ţ€“60300)
Hydraulic diagram (serial no. Ţ€“5200, US Ţ€“60300)
Hydraulic system, position list (serial no. Ţ€“5200, US Ţ€“60300)
Hydraulic system, position list (serialł no.ł 5201Ţ€“, US 60301Ţ€“)
Retarder
Retarder, functional description (serial no. Ţ€“5200, US Ţ€“60300)
STEERING
Comprehensive info, steering
General, common info about 641 – 647
Steering gear
Steering, rack and pinion gear, changing
Steering arm; steering linkage; track rod
Steering linkage, changing roller bearing in bracket (serial no. 4738Ţ€“)
Steering linkage, changing roller bearing in rear lever (serial no. 4738Ţ€“)
Steering linkage, changing roller bearing in front lever (serial no. 4738)Ţ€“
Steering linkage, checking and adjusting
Hydraulic equipment
Damping cylinder, changing seals
Damping cylinder, checking pre-load
Max. oil pressure, hydraulic system (steering and dumping), checking and adjusting
Steering cylinder, changing
Steering valve complete with connections
Steering valve, removed, reconditioning
Steering valve, changing
Supplementary steering
Secondary steering, adjusting operating pressure and stand-by (hold) pressure
FRAME; SPRINGS; DAMPING; AXLE SUSPENSION; WHEEL/TRACK UNIT
FRAME
General, common info about 711 – 718
Frame, complete
Load unit frame, checking dimensions
SUSPENSION
General, common info about 725 – 727
Hollow rubber spring, bump stop
Rubber spring, changing
FRAME LINK
Bearings
Frame joint, changing brass bushing (metallic bearing) in torque tube
Frame joint, checking and adjusting clearance
Frame joint, removed, changing brass bushing (metallic bearing)
Frame joint, removed, changing wear rings on hitch
Steering joint spherical bearings, checking clearance
Steering joint, changing spherical bearings and pivot pins
AXLE SUSPENSION
Bogie suspension
Bogie beam, changing rubber spring (oneł side)
Front or rear torsion bar, adjusting (load unit)
Torsion bar rubber bushing (rubber bearing), changing
WHEELS; TRACKS; TYRE; HUB; DRUM
Wheel
MACHINERY HOUSE; CAB; EXTERIOR TRIM PARTS ANYWHERE
CAB, NAKED; CANOPY
ENGINE HOOD; MUDGUARD; FOOT STEP
Engine hood with assembly parts
TRIM PART, OUTSIDE; GLASS; SEALING MOULDING
Glass; sealing moulding
Window pane, changing
CAB INTERIOR/UPHOLSTERY
Driver’s seat, complete; instructor’s seat
Air spring for operatorŢ€™s seat, changing
OperatorŢ€™s seat, adjusting height of attachment
OperatorŢ€™s seat, mechanical spring suspension
AIR CONDITIONING UNIT
Heating unit
Heater, changing
Cooling unit
Air conditioning, checking function
Refrigerant R134a, vacuum pumping including filling (charging)
Refrigerant R134a, draining
INTERIOR EQUIPMENT
General, common info about 881 – 884
Protection against electromagnetic interference
HYDRAULIC SYSTEM; DIGGING/ HANDLING/ GRADING EQUIPM.; MISC. EQUIP.
Diagnosis using service display unit
Hydraulic diagram, complete (steering, dumping and fan drive)
Hydraulic system (steering, dumping and fanł drive)
WORKING HYDRAULICS; SERVO HYDRAULICS
General, common info about 911 – 917
Tank; line; oil cooling; filter; breather; filling pump
Working hydraulics
Pump, working hydraulics
Hydraulic pump and dumping valve, description
Hydraulic pumps for steering and dumping system, checking internal leakage
Oil pump, ground dependent, changing
Stand-by pressure (hold pressure), disconnected and connected signal line
Servo hydraulic system
LOAD CARRIER
Hauler/platform body, incl. tipping cylinder; heating; tail gate
Dumping valve, removing and mounting
Load body, adjusting against frame
Load body, changing dump bearing