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Volvo A35E FS, Operator'S Manual

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Volvo A35E FS Operator'S Manual Download Page 149

Service and maintenance

Cab

 147

Toolbox

Toolbox (A) is positioned on the right side of the cab.

Windscreen washer reservoir

The windscreen washer reservoir (B) is positioned on the left side 
of the cab under the battery box.

Top up when required (C).

Boot box

Boot storage box (D) is positioned on the left side on the cab 
behind the battery box.

B

Window washer reservoir

C

Filling point

D

Boot  box

Summary of Contents for A35E FS

Page 1: ...OPERATOR S MANUAL Ref No VOE21C1003521 English Printed in Sweden CST ...

Page 2: ...te of California to cause cancer birth defects and other reproductive harm California Proposition 65 Warning Battery posts terminals and other related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and other reproductive harm Wash hands after handling ...

Page 3: ...factor A safety conscious person and a well maintained machine make a safe efficient and profitable combination Therefore read the safety instructions and follow them We continually strive to improve our products and to make them more efficient through changes to their design We retain the right to do this without committing ourselves to introduce these improvements on products which have already ...

Page 4: ...ordering spare parts Update the list when a component is replaced The position of the plates is shown on page 11 Please send comments about the Operator s Manual to om volvo com Manufacturer Volvo Construction Equipment AB Hauler Loader Division Carl Lihnells väg SE 360 42 BRAÅS Sweden Machine Product Identification Number Engine Transmission Dropbox Front axle Front bogie axle Rear bogie axle Cab...

Page 5: ... 57 Measures before operating 61 Starting engine 62 Gear shifting 63 Operating with differential locks 65 Steering 67 Braking 68 Stopping machine 69 Parking 70 What to do if the machine gets stuck 71 Recovering towing 72 Tipping 75 Dump body emergency lowering 76 Full Suspension emergency lowering 77 Transporting the machine 78 Operating techniques 81 Whole body vibrations 82 Transport operation 8...

Page 6: ... lubrication 162 Specifications 167 Recommended lubricants 167 Capacities and intervals between changes 171 Engine specifications 173 Fuel system specifications 174 Cooling system specifications 175 Electrical system specifications 176 Power transmission specifications 182 Brake system specifications 184 Compressed air system specifications 185 Steering hydraulic system specifications 186 Tyre siz...

Page 7: ...ust be followed and the machine be equipped for such use Contact the manufacturer dealer for further information Environmental requirements Bear the environment in mind during all operation and when servicing and maintaining the machine Always follow local and national environmental legislation that apply to all handling of the machine Engine The machine is equipped with a straight six cylinder fo...

Page 8: ... dual circuit all hydraulically controlled wet brakes with one brake circuit for the tractor unit and one for the trailer unit The brake units are fully encased oil cooled disc brakes with external cooling Exhaust retarder engine retarder Depending on the setting of certain switches exhaust brake and engine braking are available to decrease wear of the brakes Parking brake The parking brake is of ...

Page 9: ...function in the way for which it is designed Persons or organisation who carry out unauthorised modifications assume all responsibility for consequences which arise because of the modification or can be attributed to the modification including damaging affect on the machine No modifications of any kind may be carried out on this product unless each specific modification having first been approved ...

Page 10: ...required information level CareTrack makes it easier to plan for service and reduces costly downtime Productivity is improved by knowing if machines are being operated correctly and how much fuel is being consumed CareTrack also allows the customer to restrict the operating area of the machine by using virtual geographic fences This helps eliminate unauthorised machine usage and theft For further ...

Page 11: ...his manual safety must at all times and in each separate case be maintained The person carrying out such action is also responsible for the action which in some cases may require a new CE marking and the issue of a new EU Declaration of Conformity The EU EMC Directive The electronic equipment of the machine may in some cases cause interference to other electronic equipment or suffer from external ...

Page 12: ...elephone is not used For this reason it must not be placed close to other electronic equipment in the machine e g directly on a control panel or similar Guidelines The guidelines given below must be followed during installation Q The position of the aerial must be selected so that it is well adapted to the environment Q The aerial downlead must be of the coaxial cable type Make sure that the cable...

Page 13: ...late variant for markets outside the USA 1B Product plate variant for the USA market only 2 The serial number of the machine is stamped into the frame on the right side of the tractor unit by the steering joint 3 The serial number of the drive axles is positioned on the axle housing 4 The serial number of the dropbox is positioned at the back of the box to the right 5 The transmission type designa...

Page 14: ...ry a heavier load than what is stated on the decal optional equipment on machines with body height extension for light materials 5 WARNING Do not operate downhill with the gear selector in neutral Only change gear with the accelerator released 6 Air conditioning filled with R134a Opening pressure safety valve optional equipment 7 WARNING Do not use the overhung tail gate optional equipment if ther...

Page 15: ...hood 18 Service decal 19 WARNING Only use Volvo coolant VCS read the Operator s Manual 20 Brake cooling oil 21 Before transporting an FS machine on another vehicle lower the machine to bottom position 22 Retarder decal on page 85 the decal is shown in larger format and for each machine model 22 1044761 1044762 4948092 A9012200 1020820 11445056 1035003 3 5 8 12 18 25 30 50 57 3 2 5 7 11 16 18 31 34...

Page 16: ...on knowingly to remove or render inoperative such a device or element of design after the sale and delivery to the ultimate purchaser The law provides a penalty of up to 2 750 for each violation An example of a prohibited modification is the recalibration of the fuel system so that the engine will exceed the certified horsepower or torque You should not make a change to an EPA certified non road e...

Page 17: ...med on the non road engine Volvo recommends that the owner keep all records and receipts of such maintenance These records and receipts should be transferred to each subsequent purchaser of the non road engine Service Performed By Your Local Dealer Your local dealer is best suited to give you good dependable service since he has trained service technicians and is equipped with genuine original man...

Page 18: ...eather conditions below 32 ºF 0 ºC the use of lighter distillate or higher cetane level fuel are recommended Final boiling point max 660 ºF 349 ºC and cetane min 45 To avoid excessive deposit formation and to minimize the emissions of sulfur dioxide into the ambient air the sulfur content of the fuel should be the lowest available The diesel fuels recommended for use in Volvo engines should meet A...

Page 19: ...ARNING Do not operate the machine until you are thoroughly familiar with the position and function of the various instruments and controls Read through the Operator s Manual thoroughly Your safety is involved 1 Left instrument panel 3 Right instrument panel 2 Centre instrument panel 1 3 2 1008392 ...

Page 20: ...nt panel 3 Travel lights Upper end of switch pressed in lights are off Switch in centre position parking and instrument lighting switched on Lower end of switch pressed in travel and instrument lighting switched on 1 Rheostat lights in switches 4 Front working lights optional equipment 2 Rheostat instrument lighting 5 Rear working lights optional equipment 3 Travel lights 6 Keypad for display unit...

Page 21: ...king lights switched on 5 Rear working lights optional equipment Upper end of switch pressed in lights are off Lower end of switch pressed in rear working lights switched on 6 Keypad for display unit With this keypad it is possible to select any menu or function you would like to see on the display unit positioned within the main instrument see page 28 A9001500 A9001600 ...

Page 22: ... Central warning amber 15 Engine oil pressure low 3 Central warning red 16 Brake system oil pressure low 4 Charging faulty 17 Parking brake applied 5 Secondary steering system out of order 18 Service brakes applied 6 Primary steering system out of order 19 Central warning amber 7 Transmission oil temperature high 20 Display unit 8 Transmission sensor malfunctioning or faulty 21 Brake circuit oil p...

Page 23: ...lty Lights when the alternator does not provide charging voltage 5 Secondary steering system out of order Lights if the secondary steering system is out of order 6 Primary steering system out of order Lights if the primary steering system is out of order NOTE Stop the machine and investigate the cause 7 Transmission oil temperature high Lights if the transmission oil temperature is too high 8 Tran...

Page 24: ... system oil pressure low Lights if the hydraulic oil pressure in the brake system is too low 17 Parking brake applied Lights when the parking brake is applied 18 Service brakes applied Lights when the service brakes are applied 19 Central warning amber Lights flashes in case of the existence of abnormal condition Measures may have to be taken depending on the function concerned investigate the cau...

Page 25: ...n the trailer unit brake circuit 23 Fuel gauge Shows the level in the fuel tank 24 Transmission oil temperature Shows the oil temperature in the transmission 25 Tachometer The tachometer is graduated from 0 28 min 100 which means that for example 20 on the scale corresponds to 2000 revolutions per minute 26 Speedometer odometer The speedometer shows a speed of 0 80 km h 0 50 miles h and also has a...

Page 26: ...2 Safety stop engine 9 Electrically heated rear view mirrors optional equipment 3 Ignition switch 10 Electrically heated seat optional equipment 4 Cigarette lighter 11 Raised engine speed optional equipment 5 Unassigned 12 Unassigned 6 Delayed stop optional equipment 13 FS system if the machine is an FS machine 7 Hazard flashers ...

Page 27: ...eat belt with the engine running Door open Lights when the door is open When the door is open the maximum speed of the machine is limited Load and dump brake Lights when the load and dump brake function is engaged See page 69 Indicator for differential locks 6 wheel drive The lamps in the indicator light when the respective function is engaged 1 Transverse differential lock front axle 2 Longitudin...

Page 28: ...DC 15 A power socket 5 Unassigned 6 Delayed stop of engine optional equipment Upper end of switch pressed in delayed stop deactivated Lower end of switch pressed in delayed stop activated lamp in switch lights and the function will be connected if the following conditions are met gear selector in neutral N position the ignition key in position 0 turned off or position R radio position the switch i...

Page 29: ...sed in heating switched on 10 Electrically heated seat optional equipment Upper end of switch pressed in heating switched off Lower end of switch pressed in heating switched on 11 Raised engine speed optional equipment Upper end of switch pressed in raised engine speed turned off Lower end of switch pressed in raised engine speed switched on The operating speed control function will be engaged pro...

Page 30: ...s Thereafter the electronics is ready for the engine to be started and the ignition key can be turned to starting position 3 Operating information When the start up of the electronics is completed the Operating Information screen will be shown When stopping the electronics the screen will display When the ignition key is turned from position 1 to R or 0 the electronics of the machine will be close...

Page 31: ...nits time and date is carried out with the SETUP key see page 33 Engine The screens shown below become available after pressing the engine key Change screen with the arrow keys 1 ENGINE 2 TRANS MISSION 3 HYDRAULICS 4 AXLES BRAKES 5 ELECTRICAL SYSTEM 6 SERVICE 7 SETTINGS 8 ARROW UP REVERT 9 SELECT ACKNOWLEDGE 0 ARROW DOWN Engine oil Temperature C F in case of minus degrees the minus sign will be sh...

Page 32: ... rpm rpm Setting operating speed only shown if the function is available Set operating speed raised To change see page 35 rpm Transmission oil Temperature C F in case of minus degrees the minus sign will be shown at the first position Level OK V low high incorrect value Pressure OK V low incorrect value Transmission oil Temperature C F in case of minus degrees the minus sign will be shown at the f...

Page 33: ... system The screen shown below becomes available after pressing the electric system key Service The screen shown below becomes available after pressing the service key Acknowledgement of service see page 35 Hydraulic oil Temperature C F in case of minus degrees the minus sign will be shown at the first position Level OK V low incorrect value Brake cooling oil Temperature C F in case of minus degre...

Page 34: ...itor Outside temperature C F Error code is active Activated engine braking Next Service Accumulated values after setting to zero Number of operated cycles including dumping after zero setting To count as one cycle there has to be an interval of three minutes between each dumping Travelling distance after setting to zero Operating time after setting to zero Fuel consumption after setting to zero Cu...

Page 35: ...upted with the ESC key POS positive display screen AUT automatic display screen NEG negative display screen 4 Acknowledge with the select acknowledge key Setting units 1 Press the SETUP key 2 Press the arrow down key to the unit screen 3 Press the select acknowledge key 4 Browse with the arrow keys to the required setting The setting procedure may at any time be interrupted with the ESC key SI met...

Page 36: ... with the arrow keys 9 Acknowledge with the select acknowledge key Setting date 1 Press the SETUP key 2 Press the arrow down key to the date screen 3 Press the select acknowledge key 4 Browse with the arrow keys to the required setting The setting procedure may at any time be interrupted with the ESC key Year Month Day Day Month Year Month Day Year 5 Acknowledge with the select acknowledge key 6 C...

Page 37: ...ss the ESC key 2 Press the arrow down key to the screen which shows values before the zero setting 3 Press the select acknowledge key The numerals are shown in reverse image The zero setting procedure may at any time be interrupted with the ESC key 4 Acknowledge with the select acknowledge key Acknowledging service interval 1 Press the service key 2 Press the select acknowledge key The numerals ar...

Page 38: ...raising function open and remain open for 5 seconds Press on the arrow down key D to lower All solenoid valves which are connected to the lowering function open and remain open for 5 seconds As a safety measure all solenoid valves for the raising lowering function close immediately if the keys ARROW UP or DOWN are actuated again or if any other key is actuated within 5 seconds Showing of the lates...

Page 39: ...red contact a workshop authorised by Volvo CE In certain cases also the buzzer sounds at the same time as the red central warning flashes If more than one alarm occurs at the same time these will be shown one after the other If any of the alarms causes red central warning to flash and in some cases also the buzzer to sound only this alarm these alarms will be shown It is not possible to browse bet...

Page 40: ...afety stop Reduced performance between ECUs control bus J1939 High speed ECU in test mode Service info CAN Converter lockup slippage Transmission high torque transfer Transmission clutch slippage Gear selector control function Transmission overspeeding Transmission oil temperature high Transmission oil level incorrect high low Transmission oil pressure low Transmission main oil pressure low Transm...

Page 41: ...tical brake cooling oil level Low speed of brake cooling oil pump Door is open Seat belt not fastened Steering pressure from ground dependent engine dependent pump low incorrect Hydraulic oil level low Activate float mode Hydraulic oil temperature low high Tipping control not in holding position risk of crushing during dump body Dump body is up Full Suspension not in normal position P 1012063 1044...

Page 42: ...required contact a workshop authorised by Volvo CE Engine Electrical system Power transmission Lubrication and oil system Inlet and exhaust systems Engine controls Fuel system Cooling system Alternator and charging regulator Other electrical equipment Instruments sensors and warning systems Starting system Leads and fuses Transmission hydraulic Transmission mechanical Drive axles ...

Page 43: ...he function is deactivated at factory NOTE The anti theft device remains until the current is interrupted with the battery disconnect switch Use the keyboard on the left instrument panel when entering code 1 Enter the four digit code and press the select acknowledge key 2 When the entering has been completed the initial display will be shown If the wrong entry is made at any position go back by pr...

Page 44: ...Instrument panels 42 ...

Page 45: ...her controls Controls 1 Controls steering column 5 Steering wheel adjustment 2 Retarder exhaust brake 6 Brake pedal 3 Differential locks and 6 wheel drive 7 Accelerator pedal 4 Service socket 8 Control panel 1008417 1 5 6 7 8 2 3 4 ...

Page 46: ...e foot switch is pressed down See also page 66 4 Service socket Service sockets for MATRIS and VCADS Pro are positioned in the cab to the right under the steering wheel to allow readings by service personnel Control upward Headlight flasher Centre position Low beams Control downward High beams Control forward Right direction indicators Control rearward Left direction indicators Position J Intermit...

Page 47: ...6 Brake pedal Brake pedal service brakes 7 Accelerator pedal The accelerator pedal also provides possibility for exhaust brake when the pedal is fully let up depending on switch position see page 47 A Control upward The steering wheel may be raised or lowered B Control downward The steering wheel can be angled to different positions ...

Page 48: ...e gear selector 11 Load and dump brake 5 Longitudinal differential lock and 6 wheel drive if the machine is equipped with ATC see page 49 12 Tipping control 6 Transverse differential lock and 6 wheel drive if the machine is equipped with ATC see page 49 13 Lock out control for tipping control 7 Unassigned 14 Parking brake 1 2 3 13 14 12 11 5 6 7 8 4 1008419 P l ...

Page 49: ...n forward or reverse while the engine is running 5 Longitudinal differential lock and 6 wheel drive Upper end of switch pressed in longitudinal differential lock disengaged Lower end of switch pressed in longitudinal differential lock engaged NOTE Switch missing if machine is equipped with ATC Gears 1 3 0 engine braking Gear 4 35 engine braking Gear 5 65 engine braking Gears 6 9 100 engine braking...

Page 50: ...to take place a number of conditions have to be met see page 69 12 Tipping control The tipping control has four positions NOTE During loading and operating travel the lever must be in floating position 2 NOTE If the operator leaves the operator seat the tipping control automatically moves to holding position See also page 76 13 Lock out control for tipping control The purpose of lock out control i...

Page 51: ...e catch on the switch and press in the upper end of the switch Releasing if the parking brake has been applied automatically Apply and then release the parking brake with the switch Emergency brake Q In an emergency the parking brake serves as an auxiliary brake Q Should the brake pressure be lost in both service brake circuits at the same time the parking brake is applied automatically ATC Automa...

Page 52: ...eliminated so as to avoid unnecessary shaking and sudden movements IMPORTANT The instructor seat is not intended for passengers To fold down the backrest 1 First lift up the seat cushion 2 Fold down the backrest and then fold down the seat cushion IMPORTANT When the instructor seat is not used it should be collapsed and folded down A Backrest inclination B Seat inclination C Seat height D Longitud...

Page 53: ...appearance or condition Q Never make any changes to the belt or its mountings Q The seatbelt is only intended for one adult Q Keep the seatbelt rolled up retracted when it is not used Q Clean using only warm water not soap or any other cleaner Let the belt dry completely pulled out before letting it wind back on the roller Make sure that the seatbelt is installed correctly Storage space Swing up t...

Page 54: ...ontrol Stepless regulation of where the air enters the cab A All air goes through the instrument panel ventilation s nozzles B Most of the air goes through nozzles at the floor C Defroster all air is directed at the windows Fresh air control Stepless regulation of the amount of air recirculated within the cab D 90 recirculation E 50 fresh air and 50 recirculation Preferably used when the machine i...

Page 55: ...rt rain showers Do not switch off the air conditioning during short rain showers as the windows may mist up when the air conditioning stops The air conditioning only works when the engine is running and performs best when the windows are closed Ask a workshop authorised by Volvo CE to check the air conditioning once a year Climate control system adjusting These instructions are basic recommendatio...

Page 56: ...tter view to the rear The lens on the rear vision camera should be cleaned with a damp rag when required 1 SB ON ON The monitor is on all the time when the start key is in operating position SB The monitor is only on when the gear selector is in reverse The distance indicator is shown This mode is recommended as normal mode in order to not distract when operating forwards 2 LED Is alight when the ...

Page 57: ...is to apply See under Service and maintenance regarding which oil and fluid changes must be carried out during the running in period and what else applies according to the Service Programme and the Warranty Inspections Visibility It may be impossible to obtain visibility all around the machine To achieve acceptable visibility optional devices can be used e g warning systems mirrors and surveillanc...

Page 58: ...as conducted on machines with standard equipment and standard attachments If the machine is modified or equipped with other equipment or attachments resulting in reduced visibility it shall be tested again according to ISO 5006 If other equipment or attachments are used and visibility has been reduced the operator must be informed Actions before and during operation Q Walk around the machine and c...

Page 59: ...to the centre of gravity and any optional attachments Q Avoid operating with the dump body raised on ground where there is a risk of overturning for example on steep inclines or soft ground Q The machine operator must be in control of the machine s working area Prevent persons from entering the risk zone that is the area around the machine and at least 7 m beyond the attachment s max reach The ope...

Page 60: ...se the three point grip i e two hands and one foot or two feet and one hand Always face the machine do not jump Q The door must be closed when the machine is moving Q The vibration shaking which arises when operating may be harmful to the operator Reduce this by adjusting the seat selecting the most even ground adapting the travelling speed Q The cab is for the protection of the machine operator a...

Page 61: ...rve great care when working in the proximity of high voltage overhead power lines as electrical flash over may damage the machine and injure the operator at fairly great distances from the power line Bear the following in mind The distance sideways between machine and power line must be at least 2 m 6 5 ft in case of low voltage 4 m 13 ft in case of high voltage of at the most 40 kV line normally ...

Page 62: ...le which may cause obstruction Bear this in mind and pay attention to the traffic behind you Facilitate overtaking Working lights rotating beacon or hazard flashers must not to be used when travelling on public roads unless local regulations have other provisions Road signs traffic restricting arrangements and other safety devices which may be required when considering traffic speed and intensity ...

Page 63: ...e damage 4 Check that the battery disconnect switch is switched on 5 Check that the steering frame joint lock has been disconnected 6 Check that the wheels are not blocked 7 Check that engine hood and guard plates are closed 8 Check that there are no persons in the vicinity of the machine see page 57 9 Adjust the operator seat see page 50 and the steering wheel see page 45 10 Fasten the seat belt ...

Page 64: ...Run the engine at low idling speed for at least half a minute after start This is to ensure the lubrication of the turbocharger 1 Place the gear selector to neutral 2 Turn the key in the ignition switch to running position 1 so that a system test can take place the duration of which is 4 5 seconds 3 At the same time check that all lamps light up and that the gauges indicate 4 If the control lamp f...

Page 65: ...fuel consumption and performance Gear position D Normal gear position for operating forwards See also Overspeed Protection on page 65 Gear positions 1 2 and 3 Limits upshifting from gears 1 2 and 3 However upshifting is allowed to prevent overspeeding Gear position N Neutral position Gear position R Reverse gear Gear shift inhibitor Is used for preventing gearshift hunting in certain situations th...

Page 66: ...been connected count down has started it is not possible to engage a gear optional equipment If the gear selector control is moved to the N position while operating If the speed is above 7 km h 4 3 mph the transmission will not shift from the engaged gear If the speed is below 7 km h 4 3 mph the transmission will shift into Neutral If the gear selector control is moved past the N position change o...

Page 67: ...nt can be made while operating regardless of travelling speed Q The control lamp for longitudinal differential lock 6 wheel drive on the instrument panel will be alight Q The control lamp in the switch will be alight NOTE The longitudinal differential lock 6 wheel drive must be disengaged when operating on good ground and at high travelling speed Transverse differential lock front axle Q Only use ...

Page 68: ...he machine is reduced For engagement and disengagement of the differential locks see page 47 ATC Automatic Traction Control optional equipment The longitudinal differential lock and 6 wheel drive on the machine are controlled automatically The differential lock and 6 wheel drive are controlled independent of each other The machine has two possible drive combinations Q Automatic mode Q All differen...

Page 69: ...ning The steering functions as normal but if the engine dependent pumps should now stop functioning the steering of the machine will be made completely inoperable If any of the lamps are alight stop the machine immediate and contact a workshop authorised by Volvo CE Secondary steering The machine is provided with a secondary steering system which is ground dependent it is provided with a ground de...

Page 70: ...ically if the speed is above 2 km h 1 mph Q The parking brake will be applied automatically if the brake pressure should be lost in both the front and rear circuits Engine retarding Will be connected if switch A is switched on see also page 47 the accelerator pedal is fully released the engine speed exceeds 18 3 r s 1100 rpm the engine temperature exceeds 70 C 158 F Will be disconnected if the acc...

Page 71: ...e run at idle speed for at least 1 2 minute before it is stopped to ensure lubrication and cooling of the turbocharger 5 Turn the ignition key to position 0 turned off WARNING When you are entering and leaving the machine always face the machine and use the steps or hand holds to avoid slipping Always use the three point grip i e both hands and one foot or both feet and one hand when entering or l...

Page 72: ...ed components lubricate the machine thoroughly grease all unpainted surfaces tipping cylinders steering cylinders 5 Check the tyre pressure 6 Fill the fuel and hydraulic oil tanks to the max marks 7 Cover the exhaust pipe applies when parking out of doors 8 Drain water from the compressed air reservoirs 9 Remove the fuse for the voltage converter fuse 41 Otherwise there is a risk that the batterie...

Page 73: ...D and accelerate 4 Release the accelerator and brake 5 Select gear position R and accelerate again 6 Repeat this procedure until the machine has rocked loose If the machine still is stuck abort and proceed to step 3 Step 3 1 Get towing assistance from a crawler tractor a loader or an excavator 2 If you do not succeed in dumping the load because of the risk of overturning make use of a supporting m...

Page 74: ...nd have sufficient engine and braking capacity to be able to pull and stop both machines on any uphill or downhill slope Q Towing should always be done over the shortest possible distance Q Highest travelling speed during all circumstances is 10 km h 6 mph NOTE It is not possible to start the engine by towing WARNING Q The greatest care must be taken in connection with towing to avoid serious inju...

Page 75: ... see page 89 2 Block the wheels so that the machine cannot start rolling and then release all brakes 3 Release the parking brake 4 Make sure that the front or rear wheels are slightly above the ground before removing the bolts from the propeller shaft Filling compressed air system When required the compressed air system can be filled through filler valve B by using compressed air from another mach...

Page 76: ...ithout restored parking brake this shall be indicated by attaching a tag to the steering wheel stating that the parking brake is disabled Restoring parking brake after manual release 1 Block the wheels or prevent the machine from rolling in another way 2 Start the engine and leave it running until the compressed air system has reached the correct working pressure see page 185 3 Release the parking...

Page 77: ... 2 NOTE During loading and transporting this position should be selected This position is used for all operation with empty or loaded dump body This position can be used when the dump body is in such a position that it will lower under its own weight NOTE If the operator leaves the operator seat the tipping control automatically moves to holding position Holding position position 3 Is used for int...

Page 78: ...e the machine loosen the jam nut on the emergency lowering screw and screw the screw inwards Ring spanner and Allen key are included in the tool set for the machine NOTE The bolt can be turned approx 8 9 turns before actuating the tipping valve spool count the number of turns Continue to turn the screw so that it displaces the valve spool into the lowering floating position i e lowering without pr...

Page 79: ... some reason does not work there is no pressure for operating the system NOTE In order to carry out service and repairs on the machine the FS system must be in the lowered bottom position When the engine is not running but the electronics system is functional the FS system can be lowered via the operator display unit and the keyboard see page 36 If the electronics system is not functioning contact...

Page 80: ...ls Q Lash the machine through the towing eyes front and rear and against the platform on the transporting vehicle so that the machine cannot slide tip or begin to roll Q In addition to this follow national regulations Q Do not forget to unlock the steering joint and secure the steering joint lock in the bracket intended for this purpose before operating the machine again IMPORTANT If the machine i...

Page 81: ...the tool after use Q The nuts which belong to the lifting tool should preferably be stored on the tool when they are not used Q The ordinary wheel nuts should not be stored on the tool when the tool is installed on the machine Q The lifting tool is marked with two decals that state which tool and nuts should be used in combination with a certain rim and tyre The part number is also stamped in on t...

Page 82: ...e front bogie axle and tighten the nuts crosswise to 200 Nm 148 lbf ft 5 Connect four lifting slings to the lifting tools The four lifting slings must be of the same length and at least 8 5 m 28 ft 6 Lift the machine using the lifting eyes of the wheels 7 Lower the machine 8 Remove the steering frame lock before moving the machine 9 Remove the lifting tool and store the associate nuts on the wire ...

Page 83: ...es 81 Operating techniques The following pages contain advice and instructions on how to operate the machine It is important that the correct operating techniques are used to obtain safe and efficient use of the machine ...

Page 84: ...kept in good condition Remove larger stones and obstacles Fill in any ditches and holes Provide equipment and schedule time for maintaining terrain conditions Q Adjust the machine speed and chose a suitable travel path to minimise the vibration level Travel around obstacles and uneven ground Reduce the speed when it is necessary to go over rough terrain Q Maintain machines according to the manufac...

Page 85: ...isk factors The following guidelines can be effective to minimise risks of back pains Adjust the seat and controls to achieve good posture Adjust the mirrors to minimise twisted posture Provide breaks to reduce long periods of sitting Avoid jumping down from the machine Maintain reasonable weight and physical condition ...

Page 86: ...on a good road firm surface Q Also remember that the machine when fully loaded may weigh as much as 70 tonnes This requires a long braking distance especially if the road is slippery or you are travelling at high speed WARNING As the trailer unit frame is pivoted relative to the tractor unit frame around a longitudinal horizontal axis you will not feel if the trailer unit should begin to tip over ...

Page 87: ...the following operating instructions should be followed Rule Select the same gear for operating downhill as you would for operating up the same hill If you do not follow this rule you may lose control of the machine Lower the speed before the downhill Plan downhill operation so that in the first instance the retarder pedal is used in order not to overuse the service brakes on the machine WARNING Q...

Page 88: ...rehand if you are uncertain and want to avoid getting stuck Q Obtain permission from the management to operate outside the transporting route Q Where the ground is particularly soft and space permitting choose a new track for each run In this way you avoid making deep tracks NOTE Avoid operating across steep slopes and over sharp stones and tree stumps ...

Page 89: ...pped with body height extension for light material may only be used for light material The stability of the machine may be jeopardised if other heavier material is loaded in the dump body Keep a lower speed when transporting because the centre of gravity lies higher than on machines without body height extension Decal for maximum load is located on a window in the cab Transporting with load Volvo ...

Page 90: ...ability at the dump site The following applies for all dumping Before you raise the dump body make sure that no persons are close to the hauler Do not raise the dump body while reversing if the ground is uneven If the machine is placed across a steep incline move the machine before dumping the load Place the machine so that it is straight Engage the load and dump brake see page 48 Move the dump le...

Page 91: ...elease the pressure in pressurised lines and pressure vessels When work is required on the brake system or the FS system if the machine is equipped with such a system no plugs or pressure lines may be loosened before the pressure in the system has been released see page 138 4 Apply the parking brake 5 A yellow black warning label or a red flag should be attached to the steering wheel while service...

Page 92: ...d pressure in the pressurised systems If a system is opened without having first released all pressure liquid under high pressure will jet out IMPORTANT If the machine is equipped with FS system make sure that the system is in the lowered position before beginning any service work Q When looking for possible leaks use a piece of paper or stiff board not your hand Q Make sure that stepping surfaces...

Page 93: ...out service and maintenance Oil and other liquids dangerous to the environment and released into the environment will cause damage Oil degrades very slowly in water and sediment One litre of oil can destroy millions of litres of drinking water NOTE In common for all points below is that all waste is to be handed over to a treatment and disposal firm approved by the authorities Q When draining oils...

Page 94: ...s at the rear part of the plate 2 pcs The plate is heavy and therefore secured with a chain A to prevent it from falling down 2 Remove the pin for the chain and carefully let down the plate Rear guard plates Lower one plate at a time 1 First unscrew the lower bolt B 2 Hold onto the edge at the same time as the two upper bolts C are removed 3 Remove pin D and let down the plate 4 Proceed in the sam...

Page 95: ...as reached its upper end position Lowering 8 Turn the hydraulic pump valve B to the upward position with a socket wrench placed by the hydraulic pump Turn counter clockwise to end position Manual lowering 9 Take out extension C which is placed in the front grille and join it up with the socket wrench 10 Engage socket wrench D with the pump and begin to pump until the engine hood has reached its lo...

Page 96: ...port 3 Lock the tipping control in HOLDING POSITION with lock out control B When work has been completed 4 Disconnect dump body lock C or remove the dump body support 5 Disengage lock out control B from the tipping control 6 Lower the dump body IMPORTANT Always lean in under the dump body from one side when the dump body lock is to be locked or unlocked WARNING The steering joint lock must be in t...

Page 97: ...cts intended for cleaning or degreasing Also bear in mind that certain solvents may cause skin rash damage the paint finish and constitute a fire hazard Q Keep the place where the service is to be carried out clean Oil and water may make the floor slippery and are also dangerous in connection with electrical equipment or electrical tools Oily or greasy clothes are a serious fire hazard Q Check dai...

Page 98: ...re If the circumstances permit and your own safety is not endangered take the following steps at the slightest sign of fire 1 Stop the machine if it is moving 2 Turn the ignition switch to the stop position 3 Leave the cab 4 Call the fire brigade 5 Turn off the current with the battery disconnect switch unless it jeopardises your safety 6 If possible try to extinguish the fire Otherwise leave the ...

Page 99: ...otective gloves Q Grinding machine use a portable air extractor respirator and protective gloves and protective goggles Painted parts that have been discarded must never be burnt They must be taken care of by an approved refuse handling plant Rubber and plastics which have been heated Polymer materials can when heated form compounds which are dangerous to health and environment and must therefore ...

Page 100: ...veral hours without any previous warning Q The acid cannot be rinsed or washed away from the skin In stead treat with Hydrofluoric Acid Burn Jelly or similar before contacting a doctor Refrigerant NOTE All types of service of the air conditioning unit must be carried out at accredited workshops by or under the supervision of a person in a position of authority with certified competence The air con...

Page 101: ...Q If a leak is suspected leave the dangerous area and contact an accredited workshop to obtain information about what action should be taken Batteries Q Do not smoke near batteries as these give off explosive gases Q Make sure that metal objects e g tools rings and watch straps do not come into contact with the battery pole studs Q Make sure that the battery pole stud protections always are in pla...

Page 102: ...xide This dust may cause silicosis miner s consumption The employer or the management of the work site should inform the operator about any occurrence of crystalline silicon dioxide on the work site and provide special work instructions necessary protective equipment and what actions are to be taken Also check local national regulations regarding crystalline silicon dioxide and silicosis WARNING A...

Page 103: ... and for an inspection before its delivery to the customer Delivery date Please pay atten tion to the safety an d environ mental ins truc tions in Op erator s and Service Man uals for the machines concerned Pa ge 1 2 Construction Equipment Arri val inspection The arrival inspection is the first check of the product after transport Perfo rmed 1 Any deviations or transport damage must be reported to...

Page 104: ...le machine with only water Q Always lubricate the machine after washing Q Touch up the paint finish when required Paint finish maintenance Q Machines which are used in corrosive environment are more prone to rusting than others As a preventive measure it is recommended that the paint finish should be maintained every sixth months Q At first clean the machine Q Apply Dinol 77B or corresponding tran...

Page 105: ... to apply are that the oil filters are replaced every time the oil is changed the oil filters are Volvo original Long Life filter and By pass filter the oil is of a certain quality grade see page 167 the correct oil viscosity for the ambient air temperature is selected according to diagram see page 167 Follow the recommended change intervals in the table on page 168 according to the oil grade that...

Page 106: ...e draining connection 8 Install the protective cap over the draining connection on the oil sump 9 Change engine oil filter see page 105 Take care of filters oils liquids in an environmentally safe way see page 91 Filling 1 Fill with oil through oil filler pipe D 2 Put the draining hose back in the front grille 3 Hinge up the front grille Oil capacity when changing A35E A35E FS approx 49 litres 12 ...

Page 107: ...before they are installed This is to ensure lubrication immediately after start 3 Coat the gasket with oil 4 Screw on the filter by hand until the gasket just touches the sealing surface 5 Then tighten the filter a further 1 2 a turn NOTE Usually it does not help to tighten the filter harder After installing 6 Start the engine and check that the gaskets seal If it does not remove the filter and ch...

Page 108: ...n bled The fuel feed pump may be seriously damaged 1 Pump with the hand pump until a resistance can be felt in the pump NOTE No nipple is to be opened 2 Start the engine and leave it running at low idling for approx five minutes The engine speed must not be raised as any air which is left in the system may be forced into the cylinder head 3 Check that there are no error codes shown on the display ...

Page 109: ...Install the plastic bowl on the new filter 5 Coat the gasket with diesel fuel 6 Screw on the filter by hand until the gasket just touches the sealing surface 7 Then tighten the filter a further a turn 8 Reinstall the connector to the cable harness 9 Bleed the system according to instructions on the previous page Take care of filters oils liquids in an environmentally safe way see page 91 Water tra...

Page 110: ...he valve at the bottom of the filter Collect the water in a container 2 Turn back the valve when only clean fuel runs out Removing and cleaning 1 Remove the filter cover by turning the T handle counter clockwise 2 Carefully remove the filter insert with a twisting movement 3 Clean the water bowl with soapy water on a clean soft rag or brush Do not use solvents or abrasive cleaners 4 Rinse and dry ...

Page 111: ...ank full to prevent water condensing in the tank Fuel tank capacity A35E A35E FS 480 litres 127 US gal A40E A40E FS 545 litres 144 US gal For fuel quality see page 170 Fuel tank draining sludge 1 Remove the protective cap B over the drain connection located under the underbody skid plate on the right side 2 Use the same drain hose C as for engine oil drain any sediment and sludge 3 Reinstall the p...

Page 112: ...tank replacing breather filter Replace the breather filter every 1000 hours The filter is of the disposable type i e it cannot be cleaned but must be replaced 1 Remove cover A 2 Replace the filter insert 3 Reinstall the cover A Cap breather filter ...

Page 113: ...rt and a few minutes before it is stopped This is to ensure lubrication of the turbocharger The turbocharger is lubricated and cooled through the engine lubrication system A vital condition for the function of the turbocharger is that engine oil and filter are changed and replaced at regular intervals The maintenance of the air cleaner and the tightness of the exhaust system and the lubrication li...

Page 114: ...ut immediately The time between cleaning replacement depends entirely on the working environment of the machine The filter may be cleaned at the most five times Thereafter the filter must be replaced Also replace the filter if it is damaged If the control lamp continues to light after cleaning replacement the secondary filter must be replaced see page 113 NOTE At the same time clean the air cleane...

Page 115: ...ry filter is replaced Replacement must also be carried out if the control lamp continues to light after the primary filter has been cleaned or replaced Q The secondary filter B works as a protective filter in case the primary filter should be damaged Q Never remove the secondary filter unless it is to be replaced Q The secondary filter should be removed carefully and with precision so that no impu...

Page 116: ...l which is at least twice as long Oil bath air cleaner checking Check the oil in the bowl every 50 hours more often when required If the oil is contaminated by sludge and viscous or if sludge deposits are found on the underside of the filter insert the oil must be changed If there are areas on the lower filter insert covered in sludge or if there are dry spots the upper filter insert should also b...

Page 117: ... not strong enough check that there is nothing blocking the air flow in the pipe If there is no obstruction in the pipe disconnect the pipe from the silencer Check the suction in the pipe s connection on the silencer If there is still no suction change the silencer 4 Turn off the engine 5 Check that the flap is loose rattles in the non return valve C by shaking it 6 Loosen the clamp and separate t...

Page 118: ... away any dirt from the netting around the first stage 13 Assemble the cleaner in the reverse order 14 Start the engine and run at high idle 15 Check with a piece of paper that there is positive pressure at the ejector port If the piece of paper blows away from the ejector port on the precleaner s first stage then the function is satisfactory If the precleaner does not work to satisfaction contact...

Page 119: ...t when topping up or changing as the system was filled with previously IMPORTANT To avoid damage to the engine different kinds of coolant must not be mixed with each other Cooling system capacity when changing approx 90 litres 23 8 US gal Total capacity approx 100 litres 26 4 US gal If concentrated coolant and clean water see page 169 are used the table below shows the approximate amount of concen...

Page 120: ...page 30 If the coolant level is low an alarm display is shown see page 37 If the coolant temperature is high the control light is on and an alarm display is shown see page 37 Take appropriate action Check the anti freeze properties every 500 hours Coolant checking after topping up or changing The expansion tank should be filled to 2 3 i e up to the max mark when the engine is cold The coolant leve...

Page 121: ...raining nipple so that coolant flows out 3 Let down the belly plate Connect the draining hose to the nipple at the rear on the engine C 4 Connect a hose to draining nipple D 2 pcs down on the right side of the engine NOTE The cooling system does not become safe against frost even after draining There may be pockets of water left Take care of filters oils liquids in an environmentally safe way see ...

Page 122: ...m the cooling system 6 Top up until the cooling system is completely full 7 The level should be checked after the engine has been run warm and then allowed to cool IMPORTANT Never fill cold coolant in a warm engine This can cause cracking in the cylinder block and cylinder head Failure to change coolant will cause clogging of the cooling system and the risk of the engine seizing Cooling system cap...

Page 123: ...g belt Check the condition of the belt every 2000 hours The belt is self adjusting WARNING Q The engine must be stationary when checking the belt tension rotating parts can cause injuries Q The engine must never be run when the belts are completely slack 1031123 ...

Page 124: ...eries are connected in series and positioned on the left side of the machine Batteries checking electrolyte level Check the electrolyte level every 500 hours At temperatures above approx 20 C 68 F check more often The electrolyte level should be approx 10 mm 0 4 in above the cell plates Filling 1 Fill with distilled water 2 Operate the machine after topping up so that the water is mixed in with th...

Page 125: ...ry charger is set to the correct voltage 6 Switch on the charger WARNING During rapid charging of batteries always remove the cell caps When a battery is being charged an explosive mixture of oxygen and hydrogen gas is formed A short circuit an open flame or a spark in the neighbourhood of the battery can cause a powerful explosion Q Always switch off the charging current before the charging lead ...

Page 126: ...r a couple of minutes and then start the engine with the ignition key in the cab 8 When the engine has started first disconnect the jump lead from the grounding point on the machine and then disconnect the other end of the jump lead from the terminal on the booster battery 9 Finally disconnect the jump lead between the terminals 10 Reinstall the insulating caps on the battery terminals Welding NOT...

Page 127: ...d in or sign If the cables are wrongly connected the alternator rectifier will be ruined immediately Q When disconnecting batteries first break the circuit using the battery disconnect switch Alternator belt tension Check the condition of the belt for the first time at 250 hours also after replacement and then every 2000 hours Adjusting A35E A35E FS 1 Loosen bolts A on the alternator 2 Adjust with...

Page 128: ...achines with FS system the suspension system should be in normal position 3 Open the engine hood 4 Turn on high beam A or low beam B 5 Adjust the beam with the three adjusting screws 6 Turn off the high or low beams 7 Close the engine hood Left right hand traffic adjusting The headlight is supplied adjusted for right hand traffic Adjusting for left hand traffic 1 Remove screw C 2 Loosen screws D 3...

Page 129: ...hood 3 Loosen rubber boot over the electrical terminals NOTE When installing make sure that the draining tube on the rubber boot points downwards 4 Disconnect the cable terminal from the light bulb 5 Undo the locking clamp 6 Replace the light bulb 70 Watt socket H1 NOTE Do not touch the glass bulb on the new light bulb with your fingers ...

Page 130: ... Remove the protective grille three bolts 2 Remove the plate with the bulb inserts two bolts 3 Remove the bulb insert from the plate Push the rubber moulding out through the hole 4 Split the connector for the bulb insert 5 Remove the rubber moulding from the bulb insert ...

Page 131: ...nsmission to overheat Check the oil when its temperature is approx 60 C 140 F suitably at the end of the working shift 1 Place the machine in service position see page 89 2 Start the engine and let it idle 3 Move the gear selector to neutral 4 Wait for approx one minute to allow the oil level to stabilise before checking NOTE Use a rag which does not give off fluff for wiping the dipstick 5 The oi...

Page 132: ...ice position see page 89 2 Lower the guard plates 3 Remove the protective cap over the draining connection A on the oil sump 4 Connect the draining hose and drain the oil The draining hose is kept inside the front grille which can be lowered 5 Remove the draining hose and put it back inside the front grille 6 Reinstall the protective cap over the draining connection 7 Change main oil filter and lu...

Page 133: ...uitable tool for removing the filters Installing 2 Fill the filters with oil Oil capacity of each filter is approx 1 litre 0 26 US gal 3 Coat the gasket with oil 4 Then screw on the filters until the gasket just touches the sealing surface 5 Then tighten the filters a further a turn After installing 6 Start the engine and check that the gaskets seal If it does not remove the filter and check the s...

Page 134: ...cleaning The suction strainer shall be cleaned every 2000 hours Suction strainer B is located at the front on the power take off on the flywheel housing 1 Lower the guard plate and leave it suspended by the chain 2 Unscrew pipe B 3 Unscrew adapter C NOTE Approx 2 dl 8 fl oz of oil will run out 4 Take out the strainer and clean it 5 Reinstall the strainer adapter and pipe 6 Raise the guard plate WA...

Page 135: ...Fill with new oil through filler pipe C to the left at the back on the cab 5 After the oil has been changed the oil level should be checked after a short period of operation Capacity when changing approx 8 5 litres 2 2 US gal For oil quality grades see page 167 Take care of filters oils liquids in an environmentally safe way see page 91 Dropbox replacing breather filter Replace the breather filter...

Page 136: ...in the respective axle housing through the filler plug hole Level and filler plug Drive axle tractor unit right side at the front Front bogie axle left side at the back Rear bogie axle right side at the back Capacity when changing Front axle 26 litres 6 9 US gal Front bogie axle 28 litres 7 4 US gal Rear bogie axle 26 litres 6 9 US gal For oil quality grades see page 167 Take care of filters oils ...

Page 137: ...ronmentally safe way see page 91 Full Suspension checking rubber bearings Check the rubber bearings for all six FS cylinders for the first time at 4000 hours Then check every 1000 hours If the rubber bearings are worn or heavily cracked contact a workshop authorised by Volvo CE for repairs NOTE Neglected checks of the rubber bearings may lead to damaged cylinders and shortened service life of the ...

Page 138: ...by Volvo CE Manual greasing Lubricate the frame joint daily 1 Wipe off old grease from around frame joint bearing A 2 Wipe off grease nipples B and the grease gun before starting to grease 3 Pump 2 to 3 strokes at each grease nipple or until clean grease is forced out and can be seen by the seal 4 Wipe off the grease nipples after greasing is completed Automatic lubrication The machine can be equi...

Page 139: ...rvice position see page 89 2 Remove cover B above the sight glass 3 Connect the draining hose to draining connection C on the frame joint and drain off the oil 4 Remove the draining hose 5 Remove the bleeder screw 6 Fill reservoir B with new oil 7 Check the level in the sight glass NOTE Fill in stages as otherwise there is a risk that the oil will overflow 8 Install the cover and wipe off any spil...

Page 140: ...sting The parking brake is self adjusting No after adjustment is required Brake system pressure release Before carrying out any work on the brake system of the machine the pressure must be fully released This is done according to the instructions below 1 Stop the engine 2 Depress the brake pedal several times approx 30 40 times until the flow through the foot brake valve ceases When the hissing so...

Page 141: ...ol for removing the filter cover 2 Remove the filter Installing 3 Install the new filter 4 Screw on the cover WARNING Even if the engine has been stopped there is still an accumulated pressure in the brake system If the system is opened without the pressure having been released oil under high pressure will jet out V1051385 Pressure oil filter cover V1051428 Pressure oil filter ...

Page 142: ...ctive cap from the brake indicator 2 Carefully press in the indicator as far as possible with a small screwdriver Then measure the distance from the face of the nipple in to the indicator Make a note of the measurement 3 The brake linings are worn out when measurement X equals 0 mm A35E A35E FS X in the table designates new linings A40E A40E FS X in the table designates new linings If the linings ...

Page 143: ... Start the engine and leave it running a few minutes to fill the system with oil 9 Stop the engine read off at the sight glass and fill with more oil if it is required 10 Install the plug Capacity when changing approx 210 litres 55 4 US gal For oil grade see page 167 Brake cooling oil replacing oil filter Replace the oil filter every 1000 hours 1 Remove the cap from the brake cooling oil tank posi...

Page 144: ...can be drained through valve E manually Compressed air system replacing drier cartridge Replace the drier cartridge D in the air drier every 2000 hours The drier filter is positioned on the right side of the machine behind the cab Compressed air system filling When required the compressed air system can be filled through filler valve F by using compressed air from another machine The filler valve ...

Page 145: ... a wheel or if a wheel has been removed for other reasons The wheel nuts must be check tightened after 3 hours of operation Tightening torque 800 Nm 590 lbf ft NOTE Try to avoid mixing tyres from different manufacturers or tyres with different type designations on the same axle as this may lead to unnecessary wear of the drive train and also alter the properties of the machine WARNING Make sure th...

Page 146: ...cing prefilter Replace the filter every 1000 hours 1 Remove cover A 2 Slacken nuts B 3 Remove prefilter C Cab cleaning prefilter Carefully shake the filter without damaging it avoid cleaning with compressed air vacuum cleaner or water IMPORTANT Use personal protective equipment e g approved respirator when cleaning the filter Cab replacing main filter Replace the filter every 2000 hours 1 Remove s...

Page 147: ...es clean from dust as far as possible Q Tidy and vacuum clean the cab often and use personal protective equipment for instance respirator dust mask intended for asbestos contaminated areas Q The cab door must be closed It is particularly important that the tightness the seals of the cab is are preserved maintained Q The cab should be ventilated through its ventilation system which also provides ex...

Page 148: ... the precleaner rotates by looking straight into the inlet when the fan motor is running The fan blades shall rotate counter clockwise 7 Loosen the worm clamp that holds the pipe F for the outlet on the filter casing and remove the pipe from the air filter 8 Install the pipe in the new filter casing and reinstall the worm clamp IMPORTANT Make sure that no dirt gets in to the pipe Also make sure th...

Page 149: ...Windscreen washer reservoir The windscreen washer reservoir B is positioned on the left side of the cab under the battery box Top up when required C Boot box Boot storage box D is positioned on the left side on the cab behind the battery box B Window washer reservoir C Filling point D Boot box ...

Page 150: ... Make sure that the exhaust gases are extracted or removed in a suitable way Mind the hoses between compressor condenser and evaporator There is always a certain excess pressure in the system Therefore never disconnect hoses and never remove the oil filler plug on the compressor except during repairs to the system Ask a workshop authorised by Volvo CE to check the air conditioning once a year Comp...

Page 151: ... is provided with biologically degradable hydraulic oil the same type of oil must be used when topping up and when changing hydraulic oil Different types of biologically degradable hydraulic oils must not be mixed Hydraulic oil changing Change oil every 4000 hours if the system is filled with hydraulic oil or Volvo Biodegradable Hydraulic Oil Change oil every 2000 hours if the system is filled wit...

Page 152: ...rades see page 167 Take care of filters oils liquids in an environmentally safe way see page 91 Bio oil When changing from a mineral oil to a bio oil please contact a workshop authorised by Volvo CE Hydraulic system return oil filter and magnetic rods IMPORTANT Exercise cleanliness when filling oil and in all work on the hydraulic system Replace the return oil filters and clean the magnetic rods e...

Page 153: ...filter every 2000 hours The filter is positioned on the right side of the machine behind the cab wall Removing 1 Use a socket and ratchet handle or other suitable tool to remove the filter cover 2 Remove the filter Installing 3 Install the new filter 4 Screw on the cover Take care of filters oils liquids in an environmentally safe way see page 91 V1051429 Return oil filter cooling fan ...

Page 154: ...r adjusting the rubber cushions and the sideways guides IMPORTANT It is important that the area around and under the rubber cushions is kept clean Dirt which collects here considerably increases the risk of damage to the machine primarily to the frame Adjusting washers checking and adjusting dump body sideways At the rear attachment of the dump body the tipping joint a 1 mm 0 04 in clearance is pe...

Page 155: ...ntenance of exhaust flexible tube Clean and lubricate the marked parts B every 1000 hours to make sure the function is operational in case the trailer unit might overturn Lubricate the surfaces with some lubricant NOTE It is important that the lubricant is allowed to dry properly for at least 20 minutes before the exhaust pipe and the flexible exhaust tube are joined together It is important that ...

Page 156: ...ne has been involved in a collision or any kind of accident is must be taken out of operation immediately and carefully investigated regardless of when the last inspection was carried out In order to be able to carry out a correct inspection it is important that the hauler is thoroughly cleaned Early detection and repair of faults ensure continued function of the machine and improve its availabili...

Page 157: ...rt and water and prevents them from penetrating into the bearing Therefore grease the vehicle at the recommended intervals Pump 2 3 strokes or until clean grease comes out and becomes visible by the bearing Plain bearings should be greased until clean grease is forced out Wipe off grease nipples and the grease gun before greasing to avoid introducing sand and dirt particles with the grease Symbol ...

Page 158: ...Service and maintenance 156 Lubrication and service chart 10 hour 50 hour 250 hour and 500 hour service 1046083 ...

Page 159: ...according to Service Programme Measure Page Item EVERY 250 HOURS After carrying out Daily and 50 hour services Check oil level frame joint bearing 137 3 Check for leaks from dropbox visual check 133 4 Check oil level brake cooling oil 141 Check belt tension alternator and AC compressor optional equipment 125 and 148 6 Lubricate steering joints and steering cylinder rear bearings 10 Lubricate tippi...

Page 160: ...Service and maintenance 158 Lubrication and service chart ...

Page 161: ... cushions dump body 152 7 Check brake linings parking brake 138 8 Check rubber bearings on the FS cylinders 135 Replace breather filter fuel tank 110 2 Change or clean primary filter in air cleaner 112 3 Replace prefilter cab 144 4 Change oil and replace filters transmission main oil filter and lubricating oil filter 130 5 Replace return oil filter brake cooling system 141 11 Replace breather filt...

Page 162: ...Service and maintenance 160 Lubrication and service chart Checks oil changes and lubrication Intervals every 2000 hours for symbol key see page 155 ...

Page 163: ... Change breather filter frame joint bearing 137 10 Check steering joint bearings Change oil hydraulic brake systems 149 1 Replace return oil filter hydraulic brake systems 150 1 Change brake cooling oil 141 Change coolant 119 4 Replace secondary filter 113 5 Replace main filter cab 144 6 Replace filter insert oil bath air cleaner optional equipment 114 7 Replace return oil filter cooling fan 151 8...

Page 164: ...voir Fill as needed see below NOTE Too low level of lubricant results in high risk of air getting in to the system most common cause of malfunction that the system works Perform the system test on page 165 that the lubricant reservoir is not damaged that the connections seal tight that the quick couplings dust caps are installed and not damaged that the grease lines are not damaged and well fasten...

Page 165: ...upling on the filler hose 2 Fill the filler hose with grease before starting to fill This prevents air from getting in to the system 3 Remove the protective cap on the filling connection and connect the coupling on the filling connection 4 Fill lubricant to the max level on the reservoir If it is difficult to pump in lubricant either the filter behind the filling connection may be clogged or there...

Page 166: ...r 7 10 Frame joint bearing between hitch and trailer unit 2 Upper hoist cylinder 11 Steering joint 3 Dump joint 12 Steering cylinder 4 Lower hoist cylinder 13 Lower hoist cylinder 5 Steering joint 14 Dump joint 6 Upper hoist cylinder 5 4 3 2 1 1044701 6 8 12 11 13 10 9 7 14 1044702 ...

Page 167: ...d System test A system test can be performed to check the lubrication system s function or to get extra lubrication e g after washing The test button used to start a system test is located on the front of the pump A test cycle can only be run when the pump is between two normal lubrication cycles not when lubrication cycle is in progress Single lubrication test cycle The pump only runs one lubrica...

Page 168: ...es A one at a time in the dosage block that is farthest from the pump unit 3 Turn the ignition key to position 1 operating position 4 Press the test button for more than 6 seconds which corresponds to a continuous test cycle 5 When lubricant free from air comes out of the main line air bleeding is done for that main line 6 Turn the start key to 0 position and install the plug 7 Follow points 2 6 t...

Page 169: ... please contact a workshop authorised by Volvo CE for information Oil grade Recommended viscosity at varying ambient temperatures ENGINE Volvo Ultra Diesel Engine Oil or Engine oil VDS 3 or ACEA E7 VDS 2 or API CI 4 VDS 2 or EO N Premium plus VDS 2 AXLES Volvo Super Gear oil Volvo Transmission oil 97316 GO101 75W 90 FRAME JOINT Lubricating with grease Grease See page 169 Lubricating with oil Volvo...

Page 170: ...c oil is also available Contact your local Volvo service workshop for information COOLING SYSTEM Volvo Coolant VCS For further information see page 117 Sulphur content of the fuel Oil grade 0 3 0 3 0 5 0 5 Oil change interval Volvo Ultra Diesel Engine oil VDS 3 VDS 2 plus ACEA E7 500 hours 250 hours 125 hours VDS 2 plus API CI 4 VDS 2 plus EO N Premium plus VDS 2 250 hours 125 hours 75 hours VDS p...

Page 171: ...le below The concentrated coolant must not be mixed with water that contains a high degree of lime hard water salt or metals The clean water for the cooling system must also meet the following requirements If there is doubt as to the quality of the water use ready mixed coolant To avoid damage to the engine different kinds of ready mixed coolant must not be mixed with each other Freeze protection ...

Page 172: ...re products and as mixed into the diesel fuel Volvo CE accepts a maximum intermix of 5 bio diesel fuel in the diesel fuel ready mixed from the oil companies A higher intermix than 5 of bio diesel fuel may cause Increased emission by nitrogen oxide thereby not meeting legal requirements Shorter service life of engine and injection system Increased fuel consumption Altered engine output Shortening t...

Page 173: ...n incl filter and cooler 34 litres 9 0 US gal Dropbox 8 5 litres 2 2 US gal Front axle 26 litres 6 9 US gal Front the bogie axle 28 litres 7 4 US gal Rear bogie axle 26 litres 6 9 US gal Frame joint bearing between hitch and trailer unit 3 litres 0 8 US gal Hydraulic system A35E A40E 245 litres 64 7 US gal Hydraulic system A35E FS A40E FS 275 litres 72 6 US gal Brake cooling oil 210 litres 55 4 US...

Page 174: ...econdary fuel filter 500 107 Primary fuel filter 500 107 Primary filter air cleaner 1000 112 Secondary filter air cleaner 2000 113 Breather filter fuel tank 1000 110 Main oil filter 1000 131 Lubricating oil filter 1000 131 Breather filter 2000 132 Breather filter 2000 133 Breather filter 2000 135 Pressure oil filter 2000 139 Breather filter brake cooling oil tank 1000 141 Oil filter brake cooling ...

Page 175: ...the cooling fan running at basic speed With the fan at maximum speed the output is 331 kW 450 hp which coincides with DIN 70020 with the cooling fan running at basic speed With the fan at maximum speed the torque is 2374 N m 242 kgf m 1751 lbf ft which coincides with DIN 70020 Number of cylinders 6 6 Cylinder bore 130 17 mm 5 125 in 144 mm 5 669 in Stroke 150 mm 5 91 in 165 mm 6 496 in Cylinder ca...

Page 176: ...ing device Unit injectors Type Gear pump Make Bosch Feed pressure at idling speed 350 450 kPa 51 65 psi Type Electrical element Power electrical element 2 kW Time relay integrated engagement time Variable Electronically controlled regarding injection amount and injection timing Number of 6 pcs ...

Page 177: ...ing system specifications 175 Cooling system specifications Cooling fan Thermostat Type 8 blade Type Piston type thermostat Number of 1 Begins to open at 82 C 180 F Fully open at 92 C 198 F Pressure 50 kPa 0 5 bar 7 3 psi ...

Page 178: ...ut 1540 W 1540 W Current max 80 A 80 A Starter motor output 7 5 kW 10 2 hp 7 5 kW 10 2 hp Fully charged battery 1 28 kg dm3 The battery should be charged at 1 25 kg dm3 Watt Socket Headlamps 70 W H7 Parking lights 5 W Ba 15s Direction indicators 21 W Ba 15s Working lights optional equipment 70 H3 Instrument lighting 1 2 W Glass socket and integrated holder Switch 2 W Ba 9s Main instrument control ...

Page 179: ... monitor return oil filter hydraulic oil pressure monitor return oil filter cooling fan oil socket service display unit 14 5 A Low beam left 4 15 A Switch parking brake 15 5 A High beam right T ECU D EC U T EC U V EC U V2 EC U 15A 15A 15A 15A 15A 15A 15A 15A 10A R F3601 VOLVO C E 15020138 10A 5A 5A 5A 5A 42 41 40 39 5A 5A 15A 15A 38 15A 37 10A 36 5A 35 5A 34 5A 32 5A 31 5A 33 15A 30 10A 27 15A 25 ...

Page 180: ...ssion 23 10 A V T and D ECU feed 28 VDC Light load and dump brake Control lights activation red central warning 2 engaged transverse differential lock front axle engaged longitudinal differential lock engaged all differential locks 6 6 engaged transverse differential lock front bogie axle engaged transverse differential lock rear bogie axle 33 25 A Electric power outlet 28 VDC 24 15 A T ECU feed 2...

Page 181: ...seat cushion heat switch and control light turn around wheels 40 10 A Stop lights 31 15 A Cigarette lighter 41 5 A Ground tachograph 32 10 A Voltage converter switch flashing hazard lights flasher relay tachograph 42 10 A Delayed stop Marking Rated current Description fuse rail Marking Rated current Description blade fuse FC1 50 A Main fuse FH5 5 A Load and dump brake located under right control p...

Page 182: ...ision camera tachograph 6 RE3603 Buzzer central warning 16 RE3501 Working lights front 7 RE Unassigned 17 RE3502 Working lights rear T ECU D EC U T EC U V EC U V2 EC U 15A 15A 15A 15A 15A 15A 15A 15A 10A R F3601 VOLVO C E 15020138 10A 5A 5A 5A 5A 42 41 40 39 5A 5A 15A 15A 38 15A 37 10A 36 5A 35 5A 34 5A 32 5A 31 5A 33 15A 30 10A 27 15A 25 15A 26 15A 29 15A 28 5A 24 5A 23 5A 22 1 2 3 G 4 5 6 7 8 9 ...

Page 183: ...903 Load and dump brake RE8702 Climate control system AC RE3301 Starter motor down low in electrical distribution box RE8703 Climate control system AC RE3704 Delayed stop down low in electrical distribution box RE5502 Parking brake RE8704 Climate control system AC down low in electrical distribution box RE5901 Load and dump brake Marking Desig nation Description Marking Desig nation Description 10...

Page 184: ... pump Drive 4 wheel drive in permanent engagement Longitudinal In dropbox Transverse In drive axles Tractor unit Front bogie axle Rear bogie axle Make Volvo Volvo Volvo Designation A35E A35E FS ARB H35 ARB H35 ARB H35 Designation A40E A40E FS ARB H40 ARB H40 ARB H40 Tractor unit Front bogie axle Rear bogie axle Make Volvo Volvo Volvo Gear ratio A35E A35E FS 2 833 2 833 2 833 Gear ratio A40E A40E F...

Page 185: ...h 6 5 mph 4th gear 16 0 km h 9 9 mph 14 9 km h 9 3 mph 5th gear 23 0 km h 14 3 mph 21 6 km h 13 4 mph 6th gear 29 1 km h 18 1 mph 27 3 km h 17 0 mph 7th gear 38 5 km h 23 9 mph 36 0 km h 22 4 mph 8th gear 50 9 km h 31 6 mph 47 6 km h 29 6 mph 9th gear 57 0 km h 35 4 mph 57 0 km h 35 4 mph Reverse 1st gear 6 9 km h 4 3 mph 6 5 km h 4 1 mph 2nd gear 10 0 km h 6 2 mph 9 4 km h 5 8 mph 3rd gear 18 0 k...

Page 186: ...akes Parking Brake Type Dual circuit all hydraulic wet brakes One circuit for the tractor unit and one for the trailer unit Type Air mechanically and spring operated disc brake acting on the trailer unit propeller shaft Acting on both front axle and front bogie axle through the dropbox ...

Page 187: ...Compressor Compressed air reservoirs Safety valve Cut in pressure 810 730 kPa 8 1 7 3 bar 117 106 psi Cut out pressure 830 870 kPa 8 3 8 7 bar 120 126 psi Type Single cylinder piston compressor Number of 4 litres 0 14 ft3 regeneration reservoir 1 20 litres 0 7 ft3 circuit reservoir 1 Opening pressure 930 kPa 135 psi ...

Page 188: ...Double acting Double acting Tipping time 12 seconds 12 seconds Lowering time 10 seconds 10 seconds Tipping angle 70 72 A35E FS A40E FS Number of cylinders 6 6 Cylinder bore front axle 115 mm 4 45 in 115 mm 4 45 in Cylinder bore rear axles 150 mm 5 91 in 150 mm 5 91 in Piston rod diameter front axle 90 mm 3 54 in 90 mm 3 54 in Piston rod diameter rear axles 110 mm 4 33 in 110 mm 4 33 in Stroke fron...

Page 189: ...ood Year 26 5 R25 GP 4B kPa psi 375 54 5 450 65 0 Good Year 800 65 R29 GP 4D kPa psi 330 48 0 450 65 0 Michelin 26 5 R25 XADN kPa psi 350 51 0 400 58 0 Michelin 26 5 R25 XADT kPa psi 350 51 0 400 58 0 Michelin 775 65 R29 XAD kPa psi 300 44 0 375 54 5 Tyre air pressure with a load of 37 tonnes A40E A40E FS 6X6 Tyres Bridgestone 29 5 R25 VLT kPa psi 300 44 0 400 58 0 Bridgestone 29 5 R25 VLT S kPa p...

Page 190: ...ndow Heating and ventilation The basic version of the machine is provided with a heating and ventilation system with defrosting for all windows and the best possible air distribution The cab fan is a double radial fan with four speeds Air conditioning is available as optional extra Operator seat This machine is equipped with an operator seat which meets the criteria of EN ISO 7096 Height adjustmen...

Page 191: ...whole body vibration exposure to the operator using the machine For this purpose the information in ISO CEN Technical Report is recommended To ensure that the whole body vibration emission during machine use is kept to a minimum see page 82 Sound information Typical operating conditions Vibration emission value aw eqx m s RMS Vibration emission value aw eqy m s RMS Vibration emission value aw eqz ...

Page 192: ...or and full fuel tank 28100 kg 61950 lb 28500 kg 62832 lb Maximum permissible load on front axle 17700 kg 39110 lb 17800 kg 39242 lb Maximum permissible load on bogie 43900 kg 96783 lb 44200 kg 98326 lb Load capacity payload 33500 kg 73854 lb 33500 kg 73854 lb Total weight max 61600 kg 135805 lb 62000 kg 136686 lb The weights apply with 29 5 R25 tyres Service weight A40E A40E FS Front axle 15700 k...

Page 193: ...Specifications Dimensional drawing A35E A40E 191 Dimensional drawing A35E A40E The letters in the figures refer to the text on the next page 1031128 ...

Page 194: ...o dump body K 2314 mm 7 ft 7 1 in 2455 mm 8 ft 0 7 in Free tipping height L 899 mm 2 ft 11 4 in 841 mm 2 ft 9 1 in Overall height tipped dump body M 7246 mm 23 ft 9 3 in 7284 mm 23 ft 10 8 in Overall height tipped dump body M 7246 mm 23 ft 9 3 in 7449 mm 24 ft 5 3 in Outer turning radius N 8826 mm 28 ft 11 5 in 8885 mm 29 ft 1 8 in Inner turning radius N1 4426 mm 14 ft 6 3 in 4335 mm 14 ft 2 7 in ...

Page 195: ...Specifications Dimensional drawing A35E FS A40E FS 193 Dimensional drawing A35E FS A40E FS The letters in the figures refer to the text on the next page 1031129 ...

Page 196: ... Height to dump body K 2314 mm 7 ft 7 1 in 2455 mm 8 ft 0 7 in Free tipping height L 899 mm 2 ft 11 4 in 841 mm 2 ft 9 1 in Overall height tipped dump body M 7246 mm 23 ft 9 3 in 7284 mm 23 ft 10 8 in Overall height tipped dump body M 7246 mm 23 ft 9 3 in 7449 mm 24 ft 5 3 in Outer turning radius N 8826 mm 28 ft 11 5 in 8885 mm 29 ft 1 8 in Inner turning radius N1 4426 mm 14 ft 6 3 in 4335 mm 14 f...

Page 197: ...Service and maintenance Service 1000 hours Type of service Signature and stamp Date Hours Warranty Inspection Service and maintenance Service 1500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 2000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 2500 hours Type of service Signature and stamp Date Hours Service and maintena...

Page 198: ...ours Service and maintenance Service 4000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 4500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 5000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 5500 hours Type of service Signature and stamp Date Hours Service and maintenance ...

Page 199: ...ours Service and maintenance Service 7000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 7500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 8000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 8500 hours Type of service Signature and stamp Date Hours Service and maintenance ...

Page 200: ...s Type of service Signature and stamp Date Hours Service and maintenance Service 9500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 10000 hours Type of service Signature and stamp Date Hours Service and maintenance ...

Page 201: ...king belt tension 148 Condenser cleaning 148 Controls 43 Coolant 117 169 Coolant changing 119 Coolant checking 118 Coolant checking after topping up or changing 118 Cooling fan replacing return oil filter 151 Cooling system 117 Cooling system specifications 175 Delayed stop optional equipment 26 Delivery Instructions 101 Differential locks 182 Dimensional drawing A35E FS A40E FS 193 Dimensional dr...

Page 202: ...t 54 Recommended lubricants 167 Recovering 72 Recovering towing 72 Relays 180 Right instrument panel 24 Rubber cushions checking and adjusting vertically 152 Running in instructions 55 Safety regulations 1 Safety rules when operating 57 Safety valve 185 Safety when servicing 89 Seat belt 51 Secondary filter replacing 113 Secondary steering 67 Service and maintenance 101 Service brakes 68 184 Servi...

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