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Volvo EC35 Operator'S Manual Download Page 96

Service and maintenance

94

Electrical system

Electrical system

Safety regulations

Work on the electrical system must only be performed by spe-
cially trained persons and by using specified tools and test-
ing equipment.

The engine must be shut down and the battery disconnected be-

fore attempting work in the electrical system of the machine.
If running of the engine and a connected battery is required for cer-

tain test procedures, special precautions must be taken to rule out 

dangers for persons.
All electrical consumers must be switched off before installing or 

removing the battery. For removal disconnect the ground cable 

first, for installation connect the positive cable first.
Cables and plugs must be marked before disconnecting and secu-

red against contact with metal parts, e. g. by plugging on safety 

caps or by insulating.
Faults in the electrical system, e. g. damaged insulation, must be 

rectified immediately.

WARNING!

In the vicinity of the battery any sparking must be avoided! 
No open fire! Do not smoke! No ignition! DANGER OF 
EXPLOSION!

WARNING!

The battery electrolyte contains caustic sulphuric acid. If 
this comes in contact with your skin rinse it off with soap 
and lots of water. If acid has come in contact with your eyes 
or other sensitive parts of your body rinse off with lots of 
water and seek medical advice as quickly as possible.

M300091A

Summary of Contents for EC35

Page 1: ...OPERATOR S MANUAL Ref No VOE21B1002144 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: ...sign work and development activities were spent to produce a machine which meets the highest de mands with respect to safety and power Accidents occurring in spite of this are in most cases caused by human error A safety conscious person and a well maintained machine make up a safe efficient and profitable team You should therefore read and strictly observe the safety regulati ons We continually s...

Page 4: ...must be specified when contacting the manufacturer to order spare parts Positions and explanation of the PIN plates see page 9 Please send comments about the Operator s Manual to om volvo com Manufacturer Volvo Compact Equipment SAS Rue Pierre Pingon BP 119 F 01303 Belley Cedex PIN Product Identifica tion Number of machine Engine ...

Page 5: ...tions 37 General instructions 37 Safety regulations for operation 38 Measures before operation 40 Starting the engine 41 Stopping the engine 42 Loading and unloading the machine 44 Operating techniques 47 Whole body vibrations 48 Operation of the machine 50 Operating in uneven terrain or on slopes 51 Backfilling or grading 52 Stopping and parking the machine 53 Lowering the attachment 54 Hose brea...

Page 6: ...g the bearings 103 Lubrication and service chart 104 Specifications 107 Table of fuels and lubricants 107 Coolant 109 Capacities change intervals 110 Engine 111 Electrical system 112 Power Transmission 116 Slewing system 117 Cabin 118 Hydraulic system 119 Weights 121 Dimensions EC35 122 Dimensions EC45 124 Nominal lifting loads EC35 126 Nominal lifting loads EC45 128 Attachments 130 Service histor...

Page 7: ...ty con cerning maintenance care and repair in this operating instruction manual For use in special applications such as explosive environments or in areas characterised by asbestos containing dust one must com ply with particular safety regulations and the machine must be equipped for such work For further information please contact the manufacturer or your dealer Environmental requirements Bear t...

Page 8: ... hydraulic motor the oil supply of which is overpressure protected by high pressure relief valves In case of a leak or hose rupture the slewing facility is hydraulically braked Equipment A standard or quick release equipment carrier option accommo dates quick fitting of bucket or other attachments Anti theft device option The installed anti theft device seriously hampers stealing the machine Volvo...

Page 9: ...ed integral parts of the machine The CE Sign therefore also co vers our attachments We do not assume liability for attachments made by other manufacturers Materials having an effect on noise such as noise insulating noise reducing or noise absorbing materials must not be altered or re moved It is also prohibited to cut holes into cabin or engine compartment since this would have a negative effect ...

Page 10: ... transmit information to its base station even when not used For this reason it should not be placed next to electronic equipment in the machine such as directly on a control panel etc Guidelines The guidelines specified below must be followed during installation Q The position of the aerial should be chosen in such a way that it is well adapted to the environment Q The down lead from the aerial s...

Page 11: ...contains name and address of manufacturer model type designation product identification number weight of machine engine power year of manufacture as well as CE sign only in EC countries 2 Engine identification plate The engine identification plate is located on the valve cover 3 Colour code The colour code is specified on a sticker stuck to the cabin roof Volvo Compact Equipment sas Volvo Compact ...

Page 12: ...ound in the spare parts catalogue 1 Warning decal Operation and maintenance The warning decal is located under the driver s seat The instruc tions and warnings in the operator s manual must be read carefully before using the machine for the first time The technical documen tation can be found under the driver s seat 2 Warning decal Open engine hood only with engine stopped This warning decal is lo...

Page 13: ...5 Warning decal Track tension This warning decal is attached to the main chassis It indicates that the tension of the tracks must be checked every day 6 Warning decal Boom This warning decal is located under the operating console Opera te the boom only from the driver s seat North America only 7 Warning decal No ether This warning decal is located in the engine compartment Do not use ether Danger ...

Page 14: ...tory see sticker on filler neck only the oil quality specified on the sticker must be used to fill up or when changing the oil 10 Information decal Lubrication and mainte nance plan The lubrication and maintenance plan with information on lubrica tion and maintenance intervals is located under the engine hood see page 104 11 Information decal Sound capacity level This information decal is located ...

Page 15: ...____________ Z3 1490 925 665 520 ____________________________________________________________________________________ ____________________________________________________________________________________ Z2 885 710 470 430 350 ____________________________________________________________________________________ Z1 1015 900 650 505 410 345 325 _________________________________________________________...

Page 16: ...IMPORTANT Therefore hold firmly onto the machine if the machine should tip or roll over Do not jump off 20 Information decal FOPS This information decal is located on the cab above the rear winds creen FOPS Falling Object Protection Structure provides pro tection against falling down objects 21 Information decal Battery disconnecting switch This information decal is located on the ride hand side c...

Page 17: ...ucket cylinder 3 Dipper arm 4 Dipper cylinder 5 Boom 6 Boom cylinder 7 Dozer blade cylinder 8 Dozer blade 9 Boom offset cylinder 10 Main chassis 11 Travel system 12 Tracks 13 Upper structure 14 Engine hood 15 Hydraulic system cover 16 Working headlights 2 3 1 4 5 6 7 8 9 10 11 12 13 14 15 16 1012221 ...

Page 18: ...erson knowingly to remove or render inoperative such a de vice or element of design after the sale and delivery to the ul timate purchaser The law provides a penalty of up to 2 500 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 r...

Page 19: ...ts should be transferred to each subse quent purchaser of the non road engine Service Performed By Your Local Dealer Your local dealer is best qualified to give you good dependable service since he has trained service technicians and is equipped with genuine original manufacturer s parts and special tools as well as the latest technical publications Discuss your servicing and maintenance requireme...

Page 20: ...ane min 45 To avoid excessive deposit formation and to minimize the emis sions 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 ASTM designation D 975 No ID C B or No 2D T T with a cetane level above 42 and sul fur content not exceeding 0 5 percent by weight Check for fuel leaks wh...

Page 21: ...chine into operation you should become familiar with the location and function of all gauges and control elements You should therefore thoroughly read these operating instructions Your personal safety is concerned 1 Left hand instrument panel 2 Front instrument panel 3 Right hand instrument panel 4 Rear instrument panel 1 2 3 1012223 4 ...

Page 22: ...itch for rotating beacon option Operation switches the rotating beacon on and off NOTE When shutting the engine down while the rotating be acon is on the rotating beacon will stay on 3 Quick release system unlocking switch option Switch to unlock the quick release system This function is activated by simultaneous pressing of the two unlocking switches 4 Reserve option 5 Switch for working lights o...

Page 23: ... A Offset slewing control light 1 B Control light reserve option 2 Switch for working lights on boom option When actuated the working light on the boom can be swit ched on and off NOTE The working lights can only be switched on if the igni tion has been activated running position position 2 3 Switch for fast travel speed When actuated the travel speed changes A B 1012185 1012186 1012224 1 3 ...

Page 24: ... ment panel contains gauges control and warning lights During operation 3 different audible warning signals peep sounds may sound An extended warning signal after shut down with the ignition key which signalizes deactivation of the functions A triple warning signal indicates that the machine needs to be serviced standard maintenance 4 successive high pitch warning signals indicate a severe fault w...

Page 25: ...e control light is permanently on If the weight of the load is higher than the calibrated value the control light flashes A peep signal sounds at the same time Press the button again to disable this function The control light goes out 4 Fuel level gauge The fuel level gauge shows the filling level in the fuel tank Always refuel in due time thus to prevent air from entering into the fuel system A r...

Page 26: ...ng 9 Engine oil pressure control light This control light normally lights with the engine stopped and should go out when the engine is running If the control lights lights up during operation shut down the engine immediately perform trouble shooting if nec essary inform our customer service department 10 Engine temperature control light This control light flashes if the coolant temperature is too ...

Page 27: ...o 4 digit codes The machine can be protected by either one or two codes In either of these cases the engine can be started after one of the two codes is entered Both codes can be individually changed 4 Key to confirm or release a code 5 Key to edit a stored code Function 1 Insert the ignition key into the ignition switch and turn it to Run ning position position 2 the red LED 2 lights permanently ...

Page 28: ...nform the customer service department of Volvo about the serial number of the machine so that the anti theft device can be deactivated After validation you will receive the auxiliary code which ena bles you to delete both programmed codes After this you can again individually program one or two codes 3 Ignition switch The ignition switch is used for preheating and starting The ignition switch has ...

Page 29: ...ing of windscreens and optional functions 1 Cab ventilation switch 2 Switch for cleaning of windscreen 3 Reserve 4 Radio with cassette player option 1 Cab ventilation switch Two stage switch for cab ventilation 2 Switch for cleaning of windscreen Switch for windscreen wiper and washing water 3 Reserve option 1011168 1011169 1012228 1 3 4 ...

Page 30: ...7 Volume control 8 On Off 9 Display 10 Cassette player station selection 11 Automatic saving 12 Memory button 13 Memory button 14 Memory button 15 Selection 16 Eject tape 17 Tape eject Fast forward NOTE For further information on operation of the radio and cassette unit please refer to the operating instructions issued by the manufacturer 1 14 3 2 8 9 12 10 4 5 6 13 7 11 15 16 17 1011246 ...

Page 31: ... excavator attachment 3 Selector switch Slewing or Offset 4 Safety lock for working and travel hydraulics 5 Pedal for optional equipment 6 Control levers for travel motion 7 Warning horn switch 8 Right hand control lever for excavator attachment 9 Dozer blade control lever 1012118 1 8 2 3 4 5 6 7 9 ...

Page 32: ...t optional equipment North America only Control pattern selector switch see page 32 3 Selector switch Slewing or Offset When actuating this switch the control lever control changes as follows depending on the position Actuation Excavating attachment offset or Slewing move ment NOTE The slewing function is the initial control 4 Safety lock for working and travel hydraulics Move the console back to ...

Page 33: ...backward Boom up Lever to the right Empty the bucket opening Lever to the left Fill the bucket closing 8 Right hand control lever for excavator attach ment STD control pattern option Lever forward Extending the dipper arm Lever backward Retracting the dipper arm Lever to the right Empty the bucket opening Lever to the left Fill the bucket closing NOTE Market dependent optional equipment North Amer...

Page 34: ...or fast speed in the front instrument panel does not need to be activated 10 Control pattern selector switch ISO STD option The control pattern selector switch 10 is located in the tool rack This rack is located in travel direction right above the offset cylin der Lever in vertical position 1 ISO control pattern Lever in horizontal position 2 STD control pattern option NOTE Market dependent option...

Page 35: ...ot or one hand and both feet NOTE On machines with protective roof use the frame to ac cess or leave the machine Cab equipment Working lights The working lights 8 are used to illuminate the working area under insufficient light conditions The working lights are moun ted at the front standard and rear option of the cab Drawer The drawer 7 is used to store documents and onboard tools Windscreen The ...

Page 36: ...the heating at the right under the operator s seat 4 Storage compartment for operator s manuals 5 Ventilation or warm air nozzle 6 Fuses in cab 7 Washing water tank filler neck 8 Possible location for fastening a fire extinguisher 1011251 2 1 1 6 5 7 5 6 3 1012218 4 1011324 5 7 4 3 6 8 ...

Page 37: ...er weight of the operator can be adjusted on the scale 4 The value displayed by the scale 4 corresponds with the dif ferent seat hardness settings Adjusting the seat height The seat height is adjusted without having to operate a lever Pull the seat with both hands up to a higher position To raise the seat Lift the seat with both hands until it clicks audibly into place 3 positions a b and c are po...

Page 38: ...Other controls 36 Operator s seat ...

Page 39: ...h are intended to be of assistance when operating the machine However the rules do not relieve the operator from obeying local laws and other national safety regulations Alertness sensible ac tion and compliance with the safety regulations that apply for con struction sites and work places as is mandatory in order to avoid the risk of accidents and to enable safe work with the machine ...

Page 40: ...working range of the machine Do not allow persons to stand under lifted loads unless the load is secured or safely supported Do not allow persons to enter or remain in the danger zo ne i e a distance of at least 7 m to all directions around the machine in operation must be maintained The opera tor may allow a person to remain in the danger zone only when the person is within his range of vision Q ...

Page 41: ...eet and one hand on the machine Do not jump off Q Check that attachments are properly attached and locked Q Operation related vibrations may be harmful to the operator Reduce these by Correct adjustment of operator s seat and seat belt Condition of terrain for operation dips and potholes level if necessary Match travel and engine speed Q The cabin serves as protection for the operator and meets th...

Page 42: ...cess steps 5 Check that the battery disconnect switch option is switched on Additional measures under cold weather conditions Make sure that the recommended minimum temperature of the coolant complies with the weather conditions After operation The fuel tank should be filled at the end of each work day This prevents the formation of condensation water as far as pos sible The fuel tank should never...

Page 43: ...ition Ignition position 3 and start the engine As soon as the engine starts to run by its own power release the ignition key the ignition key returns to Running Position Preheating position 2 Do not continue to start for longer than 25 seconds without interruption 5 If the engine does not start turn the ignition key back to Stop Position and repeat the starting procedure NOTE Avoid excessive loadi...

Page 44: ...on console 4 in position A for interlocking The opera ting levers for working and travel hydraulics are locked no mo vement possible 6 Interrupt the electric supply with the battery disconnecting switch option Please consider that the risk of theft or burglary can be minimized by applying the following precautions Remove the key from the ignition switch if the machine is unat tended Close doors ho...

Page 45: ...nd grease bright surfaces lifting tip ping cylinders etc 3 Fill the fuel tank and the hydraulic oil tank to the max marks 4 Cover the exhaust pipe for outdoors parking 5 Make sure the coolant level in the cooling system is high enough in case of frost 6 Park the machine on level and firm ground Locations with a high risk of earth slides or flooding and the danger of freezing to the ground should b...

Page 46: ...ting points Unloading 1 Raise excavating equipment and dozer blade rotate the sle wing superstructure by 180 degrees 2 Slowly drive to the beginning of the ramp extend the excavat ing equipment position B and drive forwards until the ma chine tips on to the ramp 3 Drive down slowly until the machine reaches level ground WARNING When transporting the machine pay attention to applicable regulations ...

Page 47: ...Towing In case the machine needs to be recovered either for safety rea sons or under certain operational conditions the machine can be towed by using the towing eye located on the lower frame WARNING Do not lift the machine if there are persons inside the cab or in the immediate vicinity of the machine Use only lifting tackle of suitable stability Only lift the machine as shown Incorrect lifting c...

Page 48: ...Operating instructions 46 Loading and unloading the machine ...

Page 49: ...ages contain pieces of advice and instructions on how to operate the machine as well as examples of how to use the most common attachments The employment of the correct opera ting technique is of utmost importance for safe and efficient opera tion of the machine ...

Page 50: ...s or obstacles Fill any ditches and holes Provide equipment and schedule time to maintain terrain conditions Q Adjust the speed and travel path to minimize the vibration level Drive around obstacles and rough terrain conditions Reduce the speed when it is necessary to go over rough terrain Q Maintain machines according to the manufacturer s recommen dations Track tension Brake and steering systems...

Page 51: ...g guidelines can be effective to minimize risks of back pains Adjust the seat and controls to achieve good posture Adjust the mirrors to minimize twisted posture Provide breaks to reduce long periods of sitting Avoid jumping down from the machine Minimize repeated handling and lifting of loads Maintain reasonable weight and physical condition ...

Page 52: ...warning signal Stability when working The stability of the excavator is subjected to considerable chan ges The operator himself must observe all special regulations applicable to every operation in order to obtain full working safety WARNING If the dozer plate is in rear position 180 degree rotation travel system operation is reversed WARNING Prerequisite for good stability is that the machine is ...

Page 53: ...nchor the dozer blade into the ground behind the excavator 2 Extend the excavating equipment and place the bucket verti cally with teeth on the ground 3 Start digging by operating the bucket cylinder Simultaneously operate the bucket and the dipper arm cylinders once half of the digging cycle has been reached NOTE Do not dig the bucket too deep into the ground since this would block the digging ac...

Page 54: ...rstructure the offset can have the following values Operation of switch 3 on control lever 2 switches over to the offset function Lever to the right Lateral offset to the right Lever to the left Lateral offset to the left This work can be accomplishes under confined spatial conditions The minimum radius R1 of the excavator equipment is as follows WARNING Do not use the bottom of the bucket to leve...

Page 55: ... switch to Stop position position 1 2 All control lights go out 3 Check whether all switches and control elements are switched off or out of function 4 Pull the ignition key out of the ignition switch when it is in Stop position position 1 5 Close or lock all covers 6 Shift lever 4 of the safety interlock to position A The opera ting levers for working and travel hydraulics are locked no mo vement...

Page 56: ...can be used to lower the attachment NOTE If lowering of the attachment is not possible because the accumulator is depressurized restart the engine to pres surize the accumulator Lowering the attachment in case of pro blems with the electric circuit In case of standstill or engine defect and power failure 1 Open the lateral hood 2 Slacken screw A on the solenoid valve 3 The control elements 2 and 8...

Page 57: ...pture protection In case of standstill or engine defect and power failure during loa ding operation the accumulator pressure is sufficient to lower the attachment to the ground with the control levers WARNING If the pressure in the accumulator is no longer high enough for lowering the attachment you should secure the working area and consult an authorized Volvo CE workshop Ensure that no persons a...

Page 58: ...rective concerning the safety of machines is stated on the product plate of the machine by way of the CE Sign This cer tification therefore also covers the attachments which are desig ned and marketed by Volvo CE as they are an integral part of the machine and have been adapted to the machine Volvo CE is not reliable for attachments from other manufacturers Attachments from other manufacturers mus...

Page 59: ...ink are in line 5 Insert locking bolt 2 and secure it with the split pin 6 Remove assembly rod 1 insert locking bolt 3 and secure it with the split pin NOTE Disassembly of the bucket takes place in reverse or der WARNING Never use any attachment unless you have checked that it is securely fastened and that the attachment including hydraulic hoses hose connections and other components is free of da...

Page 60: ...t of the on board equipment which is used to ope rate the releasing mechanism on the interlocking plate 4 1 Position the quick release device under an angle of 90 2 Position the bucket 10 cm above the ground 3 Position the bar 1 on the welded bolt 2 or depending on the machine type in the opening 3 and pull the lever to unlock the plate 4 WARNING Check whether the attachment is properly locked and...

Page 61: ... tapered pin is located in the fitting groove the attach ment carrier automatically locks the bucket Removing the bucket 1 Lower the bucket to level ground 2 Press unlocking switches 1 and 3 together 3 This lifts the moveable plate 1 and unlocks the system At this time the bucket is no longer positively connected the arm can be retracted and another attachment can be fastened WARNING In order to r...

Page 62: ...NING Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all directions in order to relieve any trapped pressure It must be strictly assured that the engine cannot be started after hydraulic couplings have been opened WARNING Any persons involved in the process of changing attach ments must be familiar with the operation of the machine and s...

Page 63: ... correct function of hydrau lic connections and hydraulic system 5 Connect the hydraulic hoses of the hammer to the hydraulic connections return line A and pressure line B on the boom by sliding the hydraulic coupling C accordingly Then lock the hydraulic coupling C by turning the black safety rings D IMPORTANT Ensure correct engagement of the hydraulic connections NOTE Depending on the equipment ...

Page 64: ...tions on the boom 5 Drive the bolts 1 out of the fastening bores 2 on the boom to loosen the hammer NOTE Lay the hammer on a pallet This enables easier trans port of the hammer after disassembly WARNING Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all directions in order to relieve any trapped pressure It must be strictly assured that...

Page 65: ...the hydraulic coupling C accordingly Then lock the hydraulic coupling C with the black safety rings D IMPORTANT Ensure correct engagement of the hydraulic connections NOTE Depending on the equipment the hydraulic connec tions on the boom can vary from the illustration and the des cription WARNING In order to rule out any risk of an accident caused by unhooking of the hammer move the hammer slightl...

Page 66: ...release device with the hammer under an angle of 90 6 Insert the bar 1 into the opening 3 and press it down to un lock the plate 4 NOTE The metal bar 1 is stored between the windscreen and the control levers for travel operation NOTE Lay the hammer on a pallet This enables easier trans port of the hammer after disassembly NOTE Depending on the equipment the hydraulic connec tions on the boom can v...

Page 67: ...hanging the hammer tool The hammer tool can be changed by loosening the retaining ta pers 1 Insert a screwdriver through opening A press on latch 2 and slide it completely back into its receptacle Hold the latch de pressed 2 Insert a rod into opening B and knock out taper 1 which is no longer locked by latch 2 3 Follow the same procedure but through openings C and D to unlock and remove the second...

Page 68: ...se the wear on the hammer s bushings Q Do not swing the hammer against rocks concrete etc Q Keep the tool under a right angle to the surface of the object Apply the feed force in line with the tool Avoid minor uneven ness of the objects which could easily break off and cause idle blows or incorrect working angles If vertical structures e g brick walls are to be demolished the tool must be maintain...

Page 69: ...raulic couplings return line A and pressure line B on both sides of the dipper arm IMPORTANT Protect the hydraulic connections against dirt because only this will ensure the correct function of hydrau lic connections and hydraulic system NOTE Depending on the equipment the hydraulic connec tions on the boom can vary from the illustration and the des cription WARNING Safety regulations operating in...

Page 70: ...ipment the hydraulic connec tions on the boom can vary from the illustration and the des cription Clamshell operation The clamshell is operated with the control pedal for attachments 1 Kick down the control pedal 5 to activate the clamshell func tion 2 Release the control pedal 5 to deactivate the clamshell func tion WARNING Before removing or connecting hydraulic hoses the engine must be shut dow...

Page 71: ...are must be exercised If the machine is standing on a sloping surface the centre of gravity is displaced and during lifting a position may be reached in which the mach ine will turn over IMPORTANT For safe engine lubrication the machine must not be tilted by more than the values specified in these ope rating instructions see page 51 However please note that the machine under certain load condition...

Page 72: ...ertical index finger pointing up The hand moves in small horizontal circles LOAD VERTICAL DOWN Once arm stretched down index finger pointing down The hand moves in small horizontal circles MOVE LOAD HORIZONTALLY TOWARDS MACHINE One arm stretched out hand raised and open in direction of motion Move the hand to the desired direction MOVE LOAD HORIZONTALLY AWAY FROM MACHINE One arm stretched out hand...

Page 73: ...n of rotation of tracks or wheels SWING THE COMPLETE MACHINE Raise the forearm with the hand clo sed indicate the inside of the swinging movement The other hand performs a vertical circle Indicate the direction of rotation of tracks or wheels COUNTER ROTATION Put one hand on your head to indicate the side at which the track or wheels should turn backwards Use the other hand to perform a vertical c...

Page 74: ...hed out to the side the hand open downwards the arm moves forward and back SHUT DOWN ENGINE Move thumb or forefinger across your throat RETRACT TELESCOPIC ARM One arm stretched out horizontally in front of the body Close the hand and point the thumb to the desired direction of movement EXTEND TELESCOPIC ARM One arm stretched out horizontally in front of the body Close the hand and point the thumb ...

Page 75: ... be parked on level ground the working attachments lowered to the ground and the hydraulic system depressurized i e shut down the engine and actuate the levers for the working hydraulics several times Pull the ignition key off in order to eliminate the risk of uninten ded starting of the machine The stability of the machine is a prerequisite for safe assembly maintenance and repair work When repla...

Page 76: ...hile the engine is running Q Use a window scraper or brush with extended handle or a lad der when cleaning the outside of the windows Q Radio mobile phone or similar equipment must only be instal led by a skilled person Q When performing service work under a raised loader arm or backhoe these units must be reliably secured lifting arm or boom support or the bucket must be resting on the ground to ...

Page 77: ...highly important to learn how to use the fire extinguisher If the machine is provided with a hand held fire extinguisher it should be of the ABE type ABC in the USA Effectiveness grade I means that the time the extinguisher is effec tive must not be less that 8 seconds grade II at least 11 seconds and grade III at least 15 seconds A hand held fire extinguisher ABE I in the USA type ABC normally ha...

Page 78: ...insulating caps and that the insulation of electric cables is intact Q The following applies for welding and grinding work A fire extinguisher should be kept close at hand Sufficient ventilation must be assured for indoor works Approved respiratory equipment should be used Work surface must be cleaned Do not weld or grind on components which are filled with flammable liquids such as tanks and hydr...

Page 79: ...iratory equipment and eye protection Q Paint stripper or other chemicals Use a portable air extractor respiratory equipment and protective gloves Q Grinding machine Use a portable air extractor respiratory equipment pro tective gloves and eye protection Environmentally hazardous wastes Painted parts or parts made of plastic or rubber to be scrapped must never be burnt but should be returned to an ...

Page 80: ...immediately If a machine or part of a machine has been exposed to fire or severe heat it should be handled by specially trained personnel When handling a machine after a fire thick rubber gloves and protective goggles must be used The area around a part which has been heated up to high tempe ratures and which may be made of fluorinated rubber should be decontaminated by thorough and ample washing ...

Page 81: ...y with plenty of lime water a so lution or suspension of calcium hydroxide i e slaked lime in water As a precaution seals O rings and other oil seals should al ways be handled as if they were made of fluorinated rubber If there is a suspicion that skin has come into contact with burnt fluorinated rubber treat these skin parts with Hydrofluoric Acid Burn Jelly or something similar Seek medical advi...

Page 82: ...Safety when servicing 80 Read before servicing ...

Page 83: ...y out an arrival and delivery inspec tion Delivery instructions When handing the machine over to the customer the dealer must browse through and sign the delivery instructions together with the customer Service programmes The service program is to be used for inspections and maintenan ce work during the warranty period carried out in the workshop of a dealer authorized by Volvo CE The intervals be...

Page 84: ...mperature should not exceed 60 C 140 F Q When using a pressure cleaner keep a minimum distance of 20 30 cm 8 12 in between nozzle and machine surface Q Use a soft sponge Q Rinse the machine subsequently with clear water Paintwork care Q Machines subjected to extreme environmental conditions will corrode much quicker than other machines We recommend to treat the spray painted surfaces every six mon...

Page 85: ...nder the hood on the right hand side NOTE After loosening the screws at the fastening points the left and right hand counterweights can be folded away from the machine This enables better access to the maintenance points 1 Counterweight 2 Counterweight fastening points WARNING The machine must only be operated with properly mounted counterweights 1 2 1016530 2 1 ...

Page 86: ... accessed in the engine compartment 1 Engine oil level 2 Engine oil filler neck 3 Engine oil filter 4 Fuel filler neck 5 Fuel prefilter water separator 6 Fuel filter 7 Coolant compensation tank 8 Radiator 9 Air filter 10 Hydraulic oil cooler 11 Battery 12 Hand lamp socket 1016531 10 12 2 7 8 9 4 6 1 3 5 2 11 ...

Page 87: ...nd hood The service points for the hydraulic system components are loca ted under the right hand hood 13 Hydraulic oil level gauge 14 Hydraulic oil filler neck 15 Hydraulic oil tank 16 Hydraulic oil filter 17 Main control valve 18 Pressure accumulator 18 1016528 17 14 15 16 13 ...

Page 88: ...ut at least once per year IMPORTANT Change the oil at operating temperature and with the engine shut down 1 Unscrew the drain plug and let the old oil drain out 2 Turn the drain plug back in with a new seal ring 3 Fill new oil in through filler neck 2 until it reaches the top dip stick mark MAX Oil filling capacity in case of oil change with filter oil quality see table of fuels and lubricants on ...

Page 89: ...ew oil filter cartridge 4 Screw the cartridge on by hand until the seal touches the sur face 5 Tighten the oil filter cartridge for another half turn 6 Check the oil filter cartridge for leaks IMPORTANT Excessive tightening of the oil filter cartridge may damage the thread or the seal of the filter Type Operating hours EC35 1 Service after 100h then every 500h EC45 1 Service after 100h then every ...

Page 90: ...the drain valve 5 2 and let the collected water flow out 3 Loosen spigot nut 5 3 remove the fuel prefilter element from the fuel prefilter glass bowl 5 4 and clean it 4 Empty the fuel prefilter bowl 5 4 After this reassemble the fuel prefilter 5 Close the drain valve 5 2 again Replacing the fuel prefilter water separa tor Replace the fuel prefilter every 500 operating hours 1 Close fuel cock 5 1 T...

Page 91: ... air has entered into the fuel system for any other rea son IMPORTANT Do not start the engine before the fuel system has been bled as otherwise the injection pump may be damaged 1 Check the fuel level Replenish if required 2 Turning the ignition switch to Travel position Preheating po sition 2 see page 41 activates the fuel pump Hold the ignition switch in this position 3 Loosen the bleeding screw...

Page 92: ...and clean water see page 109 are used the table below shows the approximate amount of concentrated coolant that is required to achieve freeze protection The amount of concentrated coolant must never be less than 40 of the total mixture If there are doubts as to the quality of the water use ready mixed coolant IMPORTANT If ready mixed coolant is used it is very impor tant that the correct kind is u...

Page 93: ...ection must not be mixed see page 90 Change coolant every 2000 hours or every second year if the system is filled with Volvo Coolant VCS Change coolant every 2000 hours or every second year if the system is filled with Volvo Coolant 1 Loosen and remove the radiator cap 8 1 on the radiator 8 2 Unscrew the drain plug 8 2 and let the coolant run out 3 Take the compensation tank 7 out of bracket and e...

Page 94: ...sation tank 7 NOTE Check rubber hose and cap on compensation tank for leaks Checking the fan belt tension The tension of the fan belt should be checked every 250 ope rating hours Appropriate belt tension is an essential prerequisite for the cor rect function of the alternator and a long lifetime of the belt it self A belt of poor condition must be replaced immediately A correctly tensioned belt mu...

Page 95: ... front face verti cally against the palm of your hand or against a flat and soft sur face NOTE Avoid damaging or denting of the front face of the cart ridge 3 Blow the cartridge out with dry compressed air pressure not higher than 5 bar from inside under an oblique angle until the out flowing air is free of dust 4 Then inspect the filter with a lamp from inside to outside for pos sible cracks NOTE...

Page 96: ...e battery For removal disconnect the ground cable first for installation connect the positive cable first Cables and plugs must be marked before disconnecting and secu red against contact with metal parts e g by plugging on safety caps or by insulating Faults in the electrical system e g damaged insulation must be rectified immediately WARNING In the vicinity of the battery any sparking must be av...

Page 97: ... generator The connecting poles of the battery must never be mixed up by mistake The poles are distinctly marked with or Incor rect connection immediately damages the rectifier in the gene rator Check whether cable lugs and poles are clean well tightened and greased with Vaseline or similar Electric welding For electric welding the earth terminal must be connected di rectly to the part to be welde...

Page 98: ... the spare battery and then the cable bet ween the plus poles WARNING During the charging process oxyhydrogen will develop inside the battery A short circuit an open flame or sparks in the vicinity of the battery can cause an explosion The charging current must always be interrupted before remo ving the charging clamps Excellent ventilation must be assured especially when recharging the battery in...

Page 99: ...ting temperature 1 Before unscrewing the plugs thoroughly clean the respective areas 2 Carefully slacken the level control plug 1 release pressure before unscrewing the plug 3 Unscrew the drain plug 2 and let the gear oil run out 4 Screw drain plug 2 back in 5 Fill in oil up to the overflow point of the level inspection bore 1 6 Screw the level control plug 1 back in 7 Check the oil level after a ...

Page 100: ...racks is reached 6 In order to reduce sagging of the track press grease through grease nipple C into the adjustment cylinder 7 In order to increase sagging of the track loosen the valve unit B by one revolution so that the grease can be drained off Tighten the valve unit when the sag of the track is correct NOTE For quality of grease please refer to the table of fuels and lubricants on page 107 WA...

Page 101: ... wered for safety reasons 4 Check the hydraulic oil level in sight glass 13 The hydraulic oil level must now comply with the level shown in the illustra tion 5 If necessary fill hydraulic oil through filler neck 14 on the hy draulic oil tank 15 see page 83 Service points For quality of hydraulic oil please refer to the table of fuels and lubricants on page 107 NOTE If the hydraulic system is fille...

Page 102: ...ic oil run out 4 Screw the drain plug 15 1 back in with a new seal ring 5 Fill in new oil through the filler neck 14 up to the top of the in spection glass 13 1 6 Close filler neck 14 7 After a short test run check the hydraulic oil level in the sight glass 13 it must reach the middle of the sight glass 13 2 top up if necessary NOTE Quality of hydraulic oil see table of fuels and lubri cants on pa...

Page 103: ...rench 4 Clean the sealing surface of the filter carrier from any dirt 5 Apply some oil to the rubber seal on the new oil filter cartridge 6 Screw the cartridge on by hand until the seal touches the sur face 7 Tighten the oil filter cartridge for another half turn 8 Check the oil filter cartridge for leaks NOTE Excessive tightening of the oil filter may damage the thread or the seal of the filter 9...

Page 104: ... oil cooler may be removed from the radiator Unscrew the hydraulic oil cooler 1 Loosen the screws A on the hydraulic oil cooler 10 2 Swing the hydraulic oil cooler 10 carefully to the side Cleaning the cooling fins Clean the cooling fins on radiator 8 and hydraulic oil cooler 10 with compressed air Fasten the hydraulic oil cooler again 1 Position the hydraulic oil cooler 10 correctly 2 Tighten the...

Page 105: ...new clean grease is forced out through the outer seal For recommended lubrication grease refer to table of fuels and lubricants Wipe grease nipples and grease gun clean before greasing to keep dirt and sand out Explanation of symbols The following standard symbols are used in the lubrication and maintenance plan Lubrication Change travel gear oil Check travel gear oil Fuel system Drain condensatio...

Page 106: ...104 Lubrication and service chart Lubrication and service chart Inspection oil change and lubrication intervals EC35 EC45 Every 10 250 500 1000 and 2000 operating hours See tabular overview D D 1 5 2 2 7 4 3 5 5 9 9 8 1011315 ...

Page 107: ...he hydraulic oil level 99 Position Measures every 50 operating hours Page 2 Draining the fuel prefilter water separator 88 Position Measures after the first 100 operating hours Page 2 Draining the fuel prefilter water separator 88 5 Changing the engine oil 1st service 86 5 Changing the engine oil filter 1st service 87 9 Changing the hydraulic oil filter 1st service 101 Check the valve rocker arms ...

Page 108: ...ng the air filter cartridge 93 4 Auxiliary filter cartridge option 93 9 Changing the hydraulic oil filter 101 Check the hydraulic system pressure Position Measures every 1000 operating hours Page 7 Changing the track reduction gear oil 97 9 Changing the hydraulic oil 100 Check starter and generator Check the tightening torque of the engine mounting screws Check the valve rocker for correct adjustm...

Page 109: ...on filler neck only the oil quality specified on the sticker must be used to fill up or when changing the oil NOTE BIO OIL and mineral oil carbon hydrogen oil must be disposed of separately Mixing is prohibi ted Oil quality Viscosity under different ambient temperatures Engine Engine oil Volvo Ultra Diesel API CD CF CF 4 CI 4 Hydraulic system Hydraulic oil Volvo Super Hydraulic Oil ISO 6743 4 Bio ...

Page 110: ...nd or ester also referred to as Bio Diesel e g methyl ester or rapeseed RME is in some markets offered both as pure product or for mixing with diesel fuel Volvo CE permits an additive quantity of max 5 of bio diesel to the diesel fuel mixed in by the oil manufacturer An additive component of more than 5 of bio diesel may have the following effects increased emission of nitrogen oxides beyond the l...

Page 111: ...ontains 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 are doubts as to the quality of the water ready mixed coolant must be used To avoid damage to the eng ine different kinds of ready mixed coolant must not be mixed Freeze protection down to Mixed in amount of concentrated coolant 25 C 13 F 40 35 C 31 F 50...

Page 112: ...6 Hydraulic oil tank tank and hydraulic system 62 62 Travel gear 2 x 0 6 2 x 0 8 Oil and fluid changes Operating hours EC35 EC45 Engine oil 100 500 100 500 Coolant 2000 2000 Hydraulic oil 1000 1000 Travel gear 1000 1000 1 service Filter changes Operating hours EC35 EC45 Engine oil filter 100 500 100 500 Fuel filter 500 500 Air filter 500 500 Hydraulic oil filter 100 500 100 500 1 service ...

Page 113: ...8 x 90 mm Displacement 2190 cm3 Compression ratio 19 Fuel consumption approx 4 5 l h Firing sequence 1 3 4 2 Cooling Water Designation VOLVO D2 2 Combustion method Diesel with direct injection system Engine power net ISO 9249 26 kW 34 8 PS at 2200 min Max torque 140 kW at 1100 rpm Number of cylinders 4 Bore x stroke 88 x 90 mm Displacement 2190 cm3 Compression ratio 19 Fuel consumption approx 4 5 ...

Page 114: ...r side of the right hand operating console in the cab For functions of relays and fuses please refer to the following pages Electrical system System voltage 12 V Batteries 1 Battery voltage 12 V Battery capacity 74 Ah Three phase generator EC35 12V x 55A EC45 12V x 55A Starter motor EC35 12V 2 3 kW EC45 12V 2 3 kW A A 1 2 3 4 5 6 1011312 ...

Page 115: ...elays and fuses assignment plan Relay under the driver s seat Fuses in cab The fuse strip is located under the driver s seat Fuse strip on right hand control console see also page 34 1012178 R2 R1 R3 1 2 3 4 5 6 1011312 1011311 7 8 9 10 11 ...

Page 116: ...power supply for control unit 2 FU 20A 20 A Electric power supply for control unit 3 FU 5A 5 A Electric power supply for control unit engine preheating relay 4 FU 20A 20 A Electric power supply for lighting relay 5 FU 15A 15 A Electric power supply for cab 6 FU 15A 15 A Rotating beacon horn hand lamp No Lock Ampere Function 7 FU 3A 3 A Radio 8 FU 7 5A 7 5 A Windscreen wiper windscreen washer syste...

Page 117: ... Remedy SECURIT no warning signal The starter cannot be operated 1 Engine running 2 Left hand control console is lowered Lift the left hand control con sole ENTER CODE no warning signal Interruption of machine by activated anti theft device Anti theft device active Enter the 4 digit code and unlock the anti theft device Fault code Warning signal Fault Incident Cause Remedy FC1 01 4 audible war nin...

Page 118: ... km h 2 Gear 4 4 km h Max traction power 3630 daN 4080 daN Chassis braking system Primary brake Hydrostatic brake If the levers of the chassis control are released the machine will come to a halt Secondary brake The secondary brake is automatically applied if a fault occurs in the master brake circuit Parking brake Automatic Automatic ...

Page 119: ... remote lub rication Slewing speed directly driven Orbitrol hydraulic motor without reduction gear 10 rev min 10 rev min Brake system for slewing gear Parking brake Automatic interlocking of slewing superstructure spring friction brake Primary brake Hydrostatic brake Release slewing gear control lever in order to stop the slewing gear ...

Page 120: ...e inten ded use of the machine and should not alone be used to determine the whole body vibration exposure to the operator using the machine For this purpose the information in ISO CEN Technical Report is recom mended To ensure that the whole body vibration emission during machine use is kept to a minimum see page 48 Sound information Typical operating conditions Vibration emission value 1 4 aw eq...

Page 121: ...60 l min Rotation 23 l min Operating pressure Hydraulic system 230 bar Secondary pressure at boom at dipper arm 300 bar 300 bar EC45 Hydraulic pump 90 l min Bucket cylinder 60 51 l min Dipper cylinder 70 48 l min Boom cylinder 52 40 l min Offset cylinder 23 15 l min Dozer blade cylinder 39 29 l min Travel movement left right 60 l min one track Optional equipment 60 l min Rotation 23 l min Operatin...

Page 122: ...inder 70 45 490 Dipper cylinder 80 50 670 Boom cylinder 90 50 570 Offset cylinder 80 45 475 Dozer blade cylinder 100 60 130 EC45 Cylinder mm Bore Ø mm Rod Ø mm Stroke mm Bucket cylinder 70 45 565 Dipper cylinder 80 50 670 Boom cylinder 90 50 570 Offset cylinder 80 45 475 Dozer blade cylinder 100 60 130 ...

Page 123: ...464 kg EC45 Version Rubber tracks 400 mm Steel tracks 400 mm Cabin 4550 kg 4687 kg Cabin 4413 kg 4550 kg EC35 Version Rubber tracks 300 mm Steel tracks 300 mm Cabin 0 33 kg cm 0 033 MPa 0 34 kg cm 0 034 MPa Cabin 0 31 kg cm 0 031 MPa 0 34 kg cm 0 034 MPa EC45 Version Rubber tracks 400 mm Steel tracks 400 mm Cabin 0 25 kg cm 0 025 MPa 0 26 kg cm 0 026 MPa Cabin 0 24 kg cm 0 024 MPa 0 25 kg cm 0 025...

Page 124: ...can be changed by the manufac turer without prior notification Version EC35 Arm 1400 1700 A 5025 5055 A1 3400 3430 A2 4750 4590 B 1620 1620 C 2490 2490 C1 1550 1550 D 290 290 E 1600 1600 E1 2070 2070 F 800 800 G 1620 1620 H 1360 1360 I 370 370 K 300 300 L 1650 1650 M 3690 3690 N 510 510 N1 600 600 A2 A1 C1 H M F E E1 A G I C L K N N1 D B 1012170 ...

Page 125: ...n EC35 Arm 1400 1700 A 4840 5020 B 3530 3720 C 3170 3470 C1 3420 3710 C2 2200 2500 D 5130 5420 D1 5240 5530 D2 5090 5380 D3 3800 3900 F 510 510 G 710 710 J 1650 1650 K 700 700 L 500 500 M 190 190 N 10 10 O 600 600 R1 1575 1600 R2 1380 1380 Digging force daN 2920 daN Ripping force daN 2190 daN Offsetting angle 60 80 Total swashing angle 360 1011314 80 60 R1 R2 M N O K L J G F C1 D3 D2 D D1 C2 C A B...

Page 126: ...can be changed by the manufac turer without prior notification Version EC45 Arm 1400 1700 A 5284 5286 A1 3735 3794 A2 5018 4875 B 1800 1800 C 2539 2539 C1 1550 1550 D 320 320 E 1770 1770 E1 2284 2284 F 890 890 G 1616 1616 H 1412 1412 I 367 367 K 400 400 L 1850 1850 M 3863 3863 N 552 552 N1 651 651 A2 A1 C1 H M F E E1 A G I C L K N N1 D B 1012259 ...

Page 127: ...n EC45 Arm 1400 1700 A 4929 5081 B 3522 3674 C 3454 3753 C1 3619 3906 C2 1992 2267 D 5382 5666 D1 5501 5778 D2 5335 5616 D3 4356 4476 F 479 479 G 744 744 J 1850 1850 K 697 697 L 499 499 M 97 97 N 101 101 O 600 600 R1 1858 1911 R2 1420 1420 Digging force daN 3358 daN 2424 daN 60 80 360 Ripping force daN Offsetting angle Total swashing angle 1011316 F D3 D2 D D1 A B C2 G C C1 M N K O L R1 R2 J 80 60...

Page 128: ...nly be carried out by an authorized person WARNING Lift objects only with the lifting tackle provided for this pur pose which consists of a rod A between both sides OK 1012173 1011325 L Kg A 1011322 360 Z2 Z1 Z3 5m 3m 2m 1m 0m 5m 4m 2m 1m 0m 1m 3m 4m 2m X B A 1011323 1 5 2 2 5 3 3 5 4 4 5 4 8 Z2 955 720 570 465 ____________________________________________________________________________________ Z1...

Page 129: ... objects in lifting gear operation is prohib ited if the machine is not equipped with a Safety Kit which is optionally available and includes the following Q a safety valve on the boom Q a load safety device see switch in instrument panel Q a table stating the nominal loads for lifting gear ope ration fastened inside the operator s stand The assembly of the Safety Kit must only be carried out by a...

Page 130: ...nly with the lifting tackle provided for this pur pose which consists of a lifting eye A between both sides OK 1012173 1011326 L Kg A 1011322 360 Z2 Z1 Z3 5m 3m 2m 1m 0m 5m 4m 2m 1m 0m 1m 3m 4m 2m X B A 1 5 2 2 5 3 3 5 4 4 5 4 9 Z2 ____________________________________________________________________________________ Z1 ________________________________________________________________________________...

Page 131: ... in the cab WARNING The transport of objects in lifting gear operation is prohib ited if the machine is not equipped with a Safety Kit which is optionally available and includes the following Q a safety valve on the boom Q a load safety device see switch in instrument panel Q a table stating the nominal loads for lifting gear ope ration fastened inside the operator s stand The assembly of the Safe...

Page 132: ...175 175 125 130 STD Standard coupling manual fastening QC Quick coupling quick fastening AT Bucket teeth with adapter and locking element EC45 mm Coupling type Tooth Content l struck Content l heaped Weight kg 350 450 600 750 STD STD STD STD AT AT AT AT 58 78 110 141 70 98 142 187 87 100 122 143 350 450 600 750 QC QC QC QC AT AT AT AT 64 78 110 141 71 98 142 187 95 103 125 146 1300 1300 STD QC 123...

Page 133: ...eight kg Hydraulic oil flow l min Hydraulic pressure bar HB260 HB260 STD QC 250 250 60 60 230 230 EC45 Type Coupling type Weight kg Hydraulic oil flow l min Hydraulic pressure bar HB260 HB260 STD QC 250 250 60 60 260 260 Type Pointed chisel A Flat chisel B Spade C A B C 1016540 ...

Page 134: ...pection Maintenance after 500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 1000 hours Type of maintenance Signature and stamp Date Hours Warranty inspection Service and maintenance Maintenance after 1500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 2000 hours Type of maintenance Signature an...

Page 135: ...nd maintenance Maintenance after 3500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 4000 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 4500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 5000 hours Type of maintenance Signature and stamp Date...

Page 136: ...nd maintenance Maintenance after 6500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 7000 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 7500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 8000 hours Type of maintenance Signature and stamp Date...

Page 137: ...d maintenance Maintenance after 9000 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 9500 hours Type of maintenance Signature and stamp Date Hours Service and maintenance Maintenance after 10000 hours Type of maintenance Signature and stamp Date Hours Service and maintenance ...

Page 138: ...Specifications 136 Service history ...

Page 139: ...otection option 55 Hydraulic equipment for clamshell option 67 Hydraulic system 6 99 119 Hydraulic tools 60 Identification numbers 2 Instrument panels 19 Intended use 5 Jump starting with a spare battery 96 Left hand instrument panel 20 Lifting 45 69 Loading and unloading the machine 44 Long term parking 43 Lowering the attachment in case of problems with the electric circuit 54 Lowering the attac...

Page 140: ...Alphabetical index 138 Ref No VOE21B1002144 English Printed in Sweden CST Volvo Eskilstuna ...

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