Volvo A35D Dump Truck Service and Repair Manual PDF

Volvo A35D Dump Truck Service and Repair Manual PDF

Size: 250.64 MB
Language: English
Make: Volvo
Machine: Dump Truck
Document: Service Repair Manual, Electrical Wiring Diagram, Hydraulic Diagram
Model: Volvo A35D
Page: 5374 Pages

Detail Contents:
1.A35D
Descriptions 1

• Air cleaner, description
  Air conditioning AC, basic principles
  Alternator, description
  Brakes A35D wet brakes and A40D, description
  Brakes A35D, description
  Cab, lifting points
  Component and description
  Compressed air system, pressure build-up
  Connectors, overview
  Coolant circulation, description
  Coolant pump, description
  Cooling system, principle illustrations
  Crank mechanism, description
  Cylinder block, description
  Cylinder head, description
  Cylinder liner, description
  Damping cylinder
  Description, retarder
  Description
  Drivetrain, description
  Dropbox, general
  Dump lever, description
  Electrical distribution box, description
  Electrical system, special instructions for servicing, general
  Engine control unit
  Engine D12, description
  Engine, identification
  Exhaust pressure governor
  Fan system, description
  Filter head D12D, description
  Foot brake valve, description
  Fuel feed pump, description
  Fuel filter housing, description
  Fuel filter, description
  Fuel flow D12C
  Fuel flow, description
  Fuel system, description
  Fuel system’s components
  Function of the valves
  Function of unit injectors
  Gear F1
  Gear F2
  Gear F3
  Gear F4
  Gear F5
  Gear F6
  Hitch, specifications
  Hitch, tightening torque
  Hoist cylinder, description
  Hub end, cross-section 1
  Hub end, cross-section
  Hydraulic brake system, pressure build-up
  Hydraulic pump, description
  Hydraulic system, description
  Hydraulic tank, description
  Input and Output terminals
  Instruments and controls, climate control panel
  Instruments and controls, left instrument panel
  Instruments and controls, main instrument
  Instruments and controls, overview
  Instruments and controls, right instrument panel
  Intercooler, description
  Intermediate shaft, cut-away view
  Internal Exhaust Gas Recirculation (IEGR), description
  Lifting machine, A35D
  Load unit frame
  Lubrication system, principle
  Mechanical release of parking brake
  Oil and seals AH64J-AH64L
  Oil pump and oil cooler
  Other fuses and relays, description
  Pistons, description
  Planetary gear
  Preheating coil
  Pressure accumulation
  Pressure build-up, engine-dependent pumps, description
  Pressure check connections, description 1
  Pressure check connections, description
  Propeller shaft
  Protection against electromagnetic interference
  Radiator, description
  Repair instructions
  Reverse gear R1
  Reverse gear R2
  Rocker arm piston, D12C
  Section 4, content, structure
  Steering and dumping valve, description
  Steering cylinder, description
  Steering system, description
  Suspension, description
  Thermostat, description
  Thermostat, primary system, description
  Thermostat, secondary system, description
  Tractor unit frame
  Transmission PT1860, cut-away
  Transmission PT1862, cut-away view
  Transmission, clutches and brakes
  Turbocharger, overview illustration
  Turbocharger
  Unit injector, Bosch, description
  Unit injector, Delphi, description
  Valve mechanism, description
  VEB, activation
  VEB, description
  Water trap, description
  Windows, general

Diagrams 1

• Brake cooling oil system, diagram
  Compressed air diagram
  Electrical symbols and designations
  Explanation of wiring diagrams
  Explanations to hydraulic diagram
  Hydraulic diagram PT 1
  Hydraulic diagram PT
  Hydraulic diagram, brake system, dry brakes
  Hydraulic diagram, complete full page
  Hydraulic diagram, complete v1
  Hydraulic diagram, complete v2 full page
  Hydraulic diagram, complete v2
  Hydraulic diagram, hood opening
  Steering and dumping valve, overview illustration
  Wiring diagram A01
  Wiring diagram A01-1
  Wiring diagram A01-2
  Wiring diagram A01-3
  Wiring diagram A01-4
  Wiring diagram A02
  Wiring diagram A02-2
  Wiring diagram A03
  Wiring diagram A03-1
  Wiring diagram A03-2
  Wiring diagram A04
  Wiring diagram A04-1
  Wiring diagram A04-2
  Wiring diagram A04-3
  Wiring diagram A04-4
  Wiring diagram A05
  Wiring diagram A05-1
  Wiring diagram A05-2
  Wiring diagram A05-3
  Wiring diagram A06
  Wiring diagram A06-1
  Wiring diagram A07
  Wiring diagram A07-1
  Wiring diagram A07-2
  Wiring diagram A07-3
  Wiring diagram A08
  Wiring diagram A08-1
  Wiring diagram A08-2
  Wiring diagram A09
  Wiring diagram A09-1
  Wiring diagram A09-2
  Wiring diagram A10
  Wiring diagram A10-1
  Wiring diagram A10-2
  Wiring diagram A11
  Wiring diagram A12
  Wiring diagram A13
  Wiring diagram A14
  Wiring diagram A15
  Wiring diagram A16
  Wiring diagram A17
  Wiring diagram A18
  Wiring diagram A19
  Wiring diagram A20
  Wiring diagram A21
  Wiring diagram A22
  Wiring diagram A23 1
  Wiring diagram A23
  Wiring diagram A24
  Wiring diagram A25
  Wiring diagram A26
  Wiring diagram A27
  Wiring diagram A28
  Wiring diagrams

Installation Instructions 1

• Air cleaner, installing
  Air conditioning
  Back up alarm, installing new
  Cab heater connection 120 V, installing new
  Cab heater connection 240 V, installing new
  CareTrack, installing new
  CareTrack
  Connection for cab heater outlet
  Engine heater 240v
  Engine hood electric opening
  Extra front spill guard, installing new
  Fuel fast fill
  Load body heating
  Protection plate
  Radio installation kit
  Radio, installing new
  Rear view camera, installing new
  Rear view mirror, installing new
  Rotating beacon
  Tachograpf
  Tailgate overhung cable
  Worklamp rear
  Worklight

Repair 1

• 4-pin DIN-connectors, remounting
  88830051 User Instruction
  Accumulator, checking
  Accumulator, discarding
  Adjusting, general
  Air in fuel system, checking
  Air suspension operator’s seat, adjusting
  Alternator, changing
  Auxiliary steering, replacing hydraulic pump
  Batteries, replacing
  Bogie member, replacing incl. Bearing, replacing
  Bogie member, replacing one rubber element
  Brake caliper, reconditioning
  Brake disc
  Brake system, basic check
  Brake system, bleeding 2
  Brake system, bleeding
  Brake system, checking function, hydraulic
  Brake system, relieve pressure
  Cab door, installing door catch
  Cab door, removing door catch
  Cab, installing
  Cab, removing
  Camshaft setting, checking
  Camshaft, replacing
  Carbon dioxide in fuel system, check
  CareTrack antenna, replacing
  C-ECU, MID178, changing non-Programd ECU
  C-ECU, MID178, changing pre-Programd ECU
  Checking for leaks with inspection light
  Checking of main, torque converter and lubricating oil pressure
  Checking stalling speed
  Combined control by steering wheel, changing
  Component position 1
  Component position 2
  Component position 4
  Component position 5
  Component position 6
  Component position 7
  Component position 8
  Component position 9
  Component position 10
  Components, list and positions
  Compression test
  Compressor, replacing
  Coolant filter, changing
  Coolant pump removed, reconditioning
  Coolant, changing
  Cooling fan motor, intercooler, checking adjusting high rpm
  Cooling fan motor, intercooler, checking adjusting low rpm
  Cooling fan motor, radiator, checking adjusting high rpm
  Cooling fan motor, radiator, checking adjusting low rpm
  Cooling system, flushing
  Cooling unit, performance test
  Crankshaft, replacing rear oil seal
  Cylinder, rear flap, gas pressure, checking and adjusting
  Damping cylinder, changing seal
  Damping cylinder, checking pre-load
  Differential carrier assembly, replacing
  Dog-clutch for six-wheel drive (6×6), checking and adjusting
  Door lock, replacing
  Door window, replacing
  Door, replacing
  Dropbox, mounting
  Dropbox, removing
  Dump body alternative, lowering
  Dump body joint, changing tipping bearing
  Dump body position indicator, adjusting
  Dump body, adjusting against frame
  Dump lever, changing 1
  Dump lever, changing
  Dumping lever, checking pressure
  E-1750
  E-1763
  E-2000
  E-2502
  E-2516
  E-2519
  E-ECU, changing
  E-ECU, MID 128, changing non-Programd ECU
  E-ECU, MID 128, changing pre-Programd ECU 1
  E-ECU, MID 128, changing pre-Programd ECU
  Electric hood pump, changing 1
  Electric hood pump, changing
  Electrical system, basic check
  Engine and transmission, mounting
  Engine and transmission, removing
  Engine hood, installing
  Engine hood, removing
  Engine mounting rear, changing
  Engine rotation speed sensor (camshaft), replacing
  Engine speed sensor, changing
  Engine, basic check
  Engine, installing
  Engine, removing
  Evaporator, replacing incl draining and filling
  Fan belt and or alternator belt, checking and adjusting tension 1
  Fan belt and or alternator belt, checking and adjusting tension
  Fan motor, replacing
  Feed pump, checking feed pressure
  Foot brake valve, replacing
  Frame joint, separating the machine
  Front output shaft on dropbox, changing seal
  Front underbody skid plate, mounting
  Front underbody skid plate, removing
  Fuel pump (valves), inspection
  Fuel pump, inspection
  Fuel system, bleeding 1
  Fuel system, bleeding
  Gearshift selector, changing
  General instructions for controls, replacing.
  General maintenance instructions
  Grounding points (frame connections)
  Headlamp, high and low beams, adjusting
  Headlamp, high beam, replacing
  Headlamp, low beam, replacing
  Heat control valve, replacing
  Heat control, replacing
  Heater core, replacing
  Hoist cylinder bearing, changing
  Hoist cylinder removed, reconditioning
  Hoist cylinder, installation
  Hoist cylinder, removal
  Hydraulic pump (removed), changing shaft seal
  Hydraulic pump, checking and adjusting max working pressure 1
  Hydraulic pump, checking and adjusting max working pressure
  Hydraulic pump, checking and adjusting standby pressure
  Hydraulic pump, replacing
  Hydraulic system, bleeding air, version 1
  Hydraulic system, bleeding air, version 2
  Hydraulic system, relieve pressure
  I-ECU, MID 140, changing non-Programd ECU
  I-ECU, MID 140, changing pre-Programd ECU
  Induction sensor for turbine speed, changing
  Injectors, replacing copper sleeve in machine
  Input shaft on dropbox, changing seal
  Instructions for drilling in ROPS structure
  Intercooler, replacing
  Intermediate shaft and or bearing, changing
  Load and dump brake, checking and adjusting working pressure
  Longitudinal differential lock, checking and adjusting – from underneath
  Lubrication oil pressure, checking with pressure gauge
  Maintenance service, daily
  Maintenance service, every 50 hours
  Maintenance service, every 250 hours
  Maintenance service, every 500 hours
  Maintenance service, every 1000 hours
  Maintenance service, every 2000 hours
  Mechanical operator’s seat, adjusting
  Oil cooler, replacing
  Oil level sensor, changing
  Oil sump gasket, changing
  Operator’s seat, installing
  Operator’s seat, removing
  Output shaft 6-wheel drive, changing bearing
  Overflow valve, checking
  Parking brake lever, changing
  Parking brake, basic check
  Parking brake, replacing brake disc
  Parking brake, replacing brake pads
  Position monitor high low range, adjusting
  Power take-off, between engine and gearbox, reconditioning
  Power transmission, basic check
  Preheating coil, replacing
  Pump regulator, checking
  Radiator, adjusting
  Radiator, installing
  Radiator, mounting
  Radiator, removing
  Rear output shaft on dropbox, changing seal
  Rear window pane, replacing
  Receiver, replacing incl draining and filling
  Rubber cushion, replacing
  Seal for rear output shaft, replacing
  Secondary steering, checking and adjusting max. pressure and stand-by pressure
  Shift valve, checking
  Shut-off P1 at low engine rpm (MA9102), checking function
  Side window, replacing
  Spindle, changing 1
  Spindle, changing
  Starter motor, replacing
  Steering and dumping valve, changing
  Steering and dumping valve, removed, reconditioning
  Steering and hydraulics, basic check
  Steering and tipping valve, installation
  Steering and tipping valve, removal
  Steering cylinder, reconditioning on machine
  Steering cylinder, removed, reconditioning
  Steering cylinder, replacing bearing, left-hand side
  Steering cylinder, replacing
  Steering gear, check.and adj.
  Steering gear, replacing
  Steering joint bearing, replacing
  Steering joint spherical bearings, checking clearance
  Steering linkage, checking and adjusting 1
  Steering linkage, checking and adjusting
  Steering times, checking and adjusting
  Steering valve, neutral position, checking and adjusting
  T-ECU, MID 130, changing non-Programd ECU
  T-ECU, MID 130, changing pre-Programd ECU
  Thermostat, replacing
  Timing gear case, fitting new gasket in machine
  Transmission, installing from above
  Transmission, installing from underneath
  Transmission, removing downward
  Transmission, removing upward
  Transverse differential lock axle, checking and adjusting
  Troubleshooting tips
  Troubleshooting, air conditioning unit (AC)
  Turbocharger, inspection
  Turbocharger, replacing
  Unit injector, adjusting pretension
  Unit injector, replacing
  Vacuum pump, connection
  Valves, adjusting 1
  Valves, adjusting 22
  Valves, adjusting
  V-ECU, MID 187, changing non-Programd ECU
  V-ECU, MID 187, changing pre-Programd ECU
  Warranty inspection 100 hours
  Warranty inspection 1000 hours
  Wheel alignment
  Wheel, removing and fitting one
  Windscreen wiper front, replacing motor
  Windscreen, replacing
  Working pumps, checking function

Service Bulletins 1

• AC, time relay
  Action for reducing risk of fire
  Action to be taken in case of abnormal lubricating oil consumption
  Adaptive gear shifting for machines with R2003
  Air vent pipe, hydraulic tank
  Altered wind shield washer tank installation, improved self bleeding
  Alternative lubricants for axles with wet brakes
  A-stay, new rubber bushing
  Automatic transmission lubricants
  Axle housing, seal
  Batteries, service life
  Battery and alternator test procedure
  Bearing, output shaft, 1st bogie
  Belt guard, new type
  Brake cooling oil, altered interval between changes
  Camshaft, checking wear
  CareTrack Telematics system
  Casing, new type for headlamps
  Change of crankshaft seal
  Changed software functions in Release 2002-3
  Changing or repairing hydraulic pumps
  Charge air pressure, diesel engines
  Claim routines
  Compressed air drier, service solution
  Connector for cooling fan PWM valves
  Contronic socket, mounting plate
  Crimping Tool Set, part no. 9993880
  D9B and D12D Stage 3, valve adjustment, camshaft marking
  D12C D12D, Belt protector, new bracket
  D12C, New connecting rod
  D12D Stage III, new turbo installation
  Diesel fuels – quality and function
  Dipstick, transmission
  Door lock
  Drive axles, new hub seal
  Dropbox FL1002 FL992, new differential casing
  Dropbox, new differential
  Dropbox, new housing for longitudinal differential lock
  Dropbox, position sensor high-low
  Dropbox, service solution, reinforcement of bracket
  Engine cable harness D12C 1
  Engine cable harness D12C
  Engine oil diluted by fuel
  Engine oil requirements
  Engine oil, altered time for the first oil change
  Engine oil, interval between changes
  Engine reconditioning
  Exhaust system suspension, rubber cushion
  Fan regulator, PWM2601 and PWM2602
  Fan, new type
  FL1002 and FL992, new seals
  Fuel filter and water separator replacement interval change
  Fuel sampling, method
  Grease with molybdenum disulphide additive (MoS2)
  Grease-lubricated hitch
  Guide pins D12D
  Headlamp, new light bulb
  Hub reduction gear, new seal and spacer ring
  Hub reduction gear, planet carrier, new design
  Hydraulic oil filter, changing
  Hydraulic system, service update
  Hydraulic system, updating
  Improvements, frame joint
  Information on Bio-diesel fuel (RME-fuel)
  Information on classification of oils
  Intermediate shaft A35D A40D, new bearing and grease
  Intermittent retarder function, PT1563, 1863
  KAB Seat, heater range
  Lap belts
  Lifting tool, new marking
  Lifting tool, new type
  Lifting tool, transmission
  Lubricant, Biodegradable Hydraulic Fluid
  Measuring nipples, new type
  New AC hoses and new attaching rail
  New Caretrack WECU2
  New clamping on coolant pipe
  New coolant 1
  New coolant
  New cross stay, trailer unit
  New display screen for transmission oil level
  New dropbox
  New engine hood
  New fan installation
  New floor panel and floor mat
  New fuel filter housing
  New gas spring
  New hauler, A35D
  New haulers, A25D and A30D
  New hoist cylinder
  New Intercooler Hoses
  New keypad
  New main fuel filter, D9, D12 and D16
  New non-return valve with back-pressure function, MTRV1
  New oil dipstick
  New oil sump and level temp sensor for D12D engine
  New pressure sensors
  New rear camera system
  New rear LED flasher
  New resistor for the alternator’s charging circuit
  New seals for steering joint bearings
  New sensor for accelerator and retarder pedal
  New starter switch
  New TechToolVCADS Pro interface
  New tipping spool, valve block
  New tool Electrical repair kit, part No. 11666200
  New transmission
  New transmissions 1
  New turbocharger for the D12 engine
  New unit injectors
  New VCB valve, MA2503
  New warranty routines for Bosch diesel equipment
  New water trap
  New wiper motor
  Noise reduction kit
  Oil analyses
  Oil jet nozzle eliminated from the D12D and D9B exhaust double rocker arm
  Oil leakage from the engine cable harness grommet
  Oil sampling, method
  Oil sampling, sampling points
  Parking brake, new brake pads
  Pipe for dipstick for transmission
  Pipe, secondary water pump
  Pressure tables, transmissions
  Product development 1
  Product development
  Product update Dropbox FL1002 992, Longitudinal differential lock
  PT2509, 1563, 1863, reinforced planet kit, stage 1
  PT2509, PT1563 and PT1863 new design of spring pins in planet kit stage 2 and 3
  PTO, gear shaft assembly update
  PTO, o-rings update
  Quality of illustrations in technical reports
  Recommendations for Oil Sampling Intervals
  Repair kit, part no. 11666145, for service display
  Replacement of pivot pin for accelerator pedal and retarder pedal
  Replacement of solenoid valve MA9102
  Replacing damping cylinder
  Reporting of product misuse & near-miss report
  Reports
  Rubber bearings, cross stay
  Service and maintenance of batteries
  Service Manual, supplement
  Service solution for high altitude
  Special tools
  Spring for longitudinal differential lock in dropbox
  Steering cylinder bearing, introduction of grease nipples
  Steering joint, vertical joint, introduction of grease nipples
  Thrust washer and wear ring, axles
  Transmission PowerTronic, new B2 drum
  Transmission PowerTronic, new gasket
  Transmission PT1663, reinforced bolted joint, converter housing
  Transmission, adaptive gear shifting
  Transmission, functional check
  Transmission, improved retarder
  Transmission, inspection form
  Tyres, various types
  Valve spring update, D9, D12 and D16
  Volvo Product incidentaccident report & Interview Form

Special tool catalog

• General
  Index
  Hooks
  1. Enviroment and Safety equipment
  2. Measuring equipment
  3. Tightening and Loosening tools
  4. Lifting equipment
  5. Pullers and Pressing equipment
  6. Drifts
  7. Guide pins and Guide sleeves
  8. Pliers
  9. Fixtures
  10. Tech Tool
  11. Spare parts

Time Guide Current generation
Time Guide Old generation
Time Guide Previous generation

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