Volvo A35C Articulated Dump Truck Repair Service Manual

Description

Table of Content A35C Service Information

• GENERAL
  • DESCRIPTION, COMPLETE MACHINE
    • General
  • SPECIFICATIONS
    • • 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