2013 Volvo A35C Articulated Dump Truck Service & Repair Manual

This Volvo Construction Equipment manual delivers machine-specific repair and service information for 1996–2001 Volvo A35C articulated haulers. The service-information sheets are dated 07.03.2013.

Supplied as a single 988-page PDF in English.

• Engine and cooling: Removing and mounting the engine alongside the transmission, adjusting valve clearances, compression checks at operating temperature, and coolant-pump reconditioning.

• Drivetrain: Transmission pressure and solenoid tests, FL762 dropbox seal replacement, differential-lock adjustment, and propeller-shaft service.

• Brakes and compressed air: Service-brake bleeding, accumulator tests, parking-brake and spring-brake-cylinder repair, and LK3802 compressor service.

• Steering and dumping: Repacking steering cylinders in the machine, steering-valve reconditioning, hydraulic pump leakage tests, secondary-steering adjustment, and dumping-valve replacement.

• Frame and suspension: Separating and assembling the tractor and load units at the frame joint, bearing replacement, bogie suspension repairs, and dump-bearing service.

• Electrical diagnosis: Serial-specific wiring diagrams, connector illustrations, Contronic fault charts, and sensor and solenoid resistance checks.

The diagnostic procedures and heavy assembly work suit experienced heavy-equipment technicians with access to service-display equipment, pressure gauges, and suitable lifting gear.

Engine and Drivetrain Coverage

Through serial 5200 / US 60300: TD122 KAE engine (product no. 499189), PT1761 transmission (11037935), and AH 63 G and AH 63 H bogie axles.

From serial 5201 / US 60301: TD122 KME engine (8188161), PT1761A transmission (11038035), and AH 63 Y and AH 63 Z bogie axles. Both configurations use the AH 63 L front axle and FL762 dropbox (22505).

Engine service: Fuel-feed pressure checks, injector replacement, fuel-system bleeding, injection timing, and automatic timing-adjuster checks supplement the engine procedures.

Cooling coverage distinguishes the engine and intercooler circuits and includes radiator replacement, hydraulic fan-drive testing, fan-speed adjustment, and fan-motor reconditioning.

The fuel-system cautions explain why bending the preformed injection lines can cause them to rupture.

Transmission diagnosis: Main, torque-converter, and lubrication-pressure tables accompany troubleshooting for harsh shifts, lost lock-up, and weak retarder action. The transmission hydraulic diagram identifies the clutch, brake, modulation, and retarder circuits.

Removal instructions flag the risk of an unsecured torque converter slipping out and being damaged.

Overhaul scope: This is machine service information, not a set of complete component overhaul manuals. It refers to separate service manuals for the engine, transmission, dropbox, and drive axles; those separate publications are not included.

Brake, Steering and Hydraulic Repair

The service brakes are hydraulic, with separate tractor-unit and load-unit circuits; the spring-applied parking brake is released by compressed air.

Brake coverage includes caliper and disc replacement, foot-brake-valve reconditioning, unloading-valve service, and serial-specific bleeding instructions. Compressed-air diagrams show the connections for the parking brake, differential locks, and range selection.

Hydro-mechanical steering: Linkage adjustment and damping-cylinder checks address wandering, oscillation, and sluggish steering. Standby-pressure checks distinguish pump settings from steering-valve signal pressure.

The complete steering, dumping, and fan-drive hydraulic diagram shows the shared pump arrangement and the ground-driven secondary-steering pump. The documentation covers hydraulic control valve specifications, variable piston pump data, and performance data for the 3-stage hoist cylinders, including their double-acting inner stage.

Electrical Systems and Contronic

Electrical sections outline starter motor output and alternator requirements, with fuse and relay layouts, cable identification tables, and connector pin illustrations. Wiring coverage includes Circuit 2: Automatic gearshifting and Circuit 9: Contronic, with early and late serial-number versions.

Diagnostic chapters explain how to interpret the Contronic Information display unit for system monitoring, with separate coverage of the Service display unit.

The diagnostic charts connect symptoms and error codes to electrical checks, helping distinguish a failed sensor from a wiring fault before replacing components.

The troubleshooting sections specify service display unit 999 3721, multimeter 11 666 140, and multi-pin breaker box 11 668 002. Electric-speedometer calibration and electronic-speedometer programming are also covered.

Frame, Cab and Workshop References

Frame-joint procedures cover clearance measurement, bushing replacement, wear rings, spherical bearings, and pivot pins. Bogie work includes rubber springs, rubber bushings, and torsion-bar adjustment; dimensional views support frame checks and load-body alignment.

Cab air-conditioning sections cover function checks, R134a recovery, evacuation, charging, and leak testing. They describe the FRS-10GS recycling station and distinguish R134a service equipment from R12 equipment.

The factory Time Guide lists operation codes and labor allowances. Reference sections provide component-specific torque tables, fluid capacities, wear limits, and electrical test values.

E-tool welding, detail, and composite drawings include the E 1057C transmission lifting device and E 1645 load-body support.

Any actual maintenance or heavy lifting should rely directly on the procedures and safety requirements in the Volvo documentation, particularly for raised load bodies and stored brake pressure.

PDF Navigation and Diagram Readability

The page total includes the eight-page Time Guide and 31 pages of E-tool drawings. Text search and embedded PDF bookmarks are not available, and some internal cross-references display unresolved placeholders. Small wiring labels require zooming; some characters remain pixelated or indistinct.