A35E/A35E FS / A40E/A40E FS

A35E/A35E FS / A40E/A40E FS

Foreword

This Operator's Manual is intended as a guide for the correct use and maintenance of the machine. Therefore, study it carefully before starting and operating the machine, or before carrying out any preventive maintenance.

Keep the manual in the cab so that it always is at hand.

Replace it immediate if it is lost.

The manual describes the applications for which the machine primarily is intended and is written to apply for all markets.

We therefore ask you to disregard the sections which are not applicable to your machine or to the work for which you use your machine.

NOTE! The information in the manual applies to machine models A35E, A35E FS, A40E and A40E FS, unless otherwise stated.

Many hours are spent on design and production to make a machine that is as efficient and safe as possible. The accidents which occur in spite of this, are mostly caused by the human 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 been delivered. We also retain the right to change data and equipment, as well as instructions for service and other maintenance measures without prior notice.

OPERATOR'S MANUAL

Table of contents

Presentation

Instrument panels

Other controls

Operating instructions

Operating techniques

Safety regulations

It is the operator's obligation to know and follow the applicable national and local safety regulations. The safety instructions in this manual only apply to cases when there are no national or local regulations.

Safety when servicing

WARNING!

The symbol above appears at various points in the manual together with a warning text. It means:

Warning, be alert! Your safety is involved! It is the obligation of the operator to make sure that all warning decals are in place on the machine and that they are

readable. Accidents may otherwise occur.

Service and maintenance

Specifications

Alphabetical index

Get to know the capacity and limits of your machine!

Ref.No. VOE21C1003521

The original language is Swedish

Printed in Sweden, 2009.03

Copyright © 2009, Volvo Construction Equipment Customer Support. All rights reserved.

2

Foreword

Identification numbers

Identification numbers

State the identification number of the machine and the components below. The number should be stated when contacting the manufacturer and when ordering spare parts. Update the list when a component is replaced. The position of the plates is shown on page 11.

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

Please send comments about the Operator's Manual to [email protected]


3


Foreword....................................................................1

Identification numbers ............................................................ 2

Presentation ..............................................................5

CE marking, EMC directive .................................................... 9

Communication equipment, installation................................ 10

Plates and decals ................................................................. 11

The USA Federal Clean Air Act............................................ 14

Instrument panels ...................................................17

Left instrument panel ............................................................ 18

Centre instrument panel ....................................................... 20

Right instrument panel.......................................................... 24

Display unit ........................................................................... 28

Other controls .........................................................43

Controls ................................................................................ 43

Operator comfort .................................................................. 50

Ventilation system ................................................................ 52

Operating instructions ...........................................55

Safety rules when operating ................................................. 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 .............................................................. 84

Operating on inclines............................................................ 85

Off-road operation ................................................................ 86

Loading................................................................................. 87

Transporting with load .......................................................... 87

Dumping load ....................................................................... 88

Safety when servicing ............................................89

Service position .................................................................... 89

Before service, read ............................................................. 90

Preparations before service.................................................. 92

Fire protection....................................................................... 95

Handling hazardous substances .......................................... 97

4


Service and maintenance.....................................101

Engine ................................................................................ 103

Fuel system ........................................................................ 106

Intercooler........................................................................... 111

Turbocharger ...................................................................... 111

Air cleaner .......................................................................... 112

Additional air cleaner .......................................................... 114

Cooling system ................................................................... 117

Electrical system................................................................. 122

Power transmission ............................................................ 129

Brake system...................................................................... 138

Compressed-air system...................................................... 142

Tyres................................................................................... 143

Cab ..................................................................................... 144

Hydraulic system ................................................................ 149

Dump body ......................................................................... 152

General inspection of machine ........................................... 154

Lubrication and service chart.............................................. 155

Automatic greasing............................................................. 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 sizes and recommended air pressure ........................ 187

Cab, specifications ............................................................. 188

Weights............................................................................... 190

Dimensional drawing, A35E/A40E...................................... 191

Dimensional drawing, A35E FS/A40E FS .......................... 193

Service history .................................................................... 195

Alphabetical index ................................................199

Presentation

Presentation

5

1031100

Volvo A35E/A35E FS 6×6 is a three-axle, sprung hauler with articulated frame steering and a load capacity of 33.5 tonnes

(36.9 sh tons) or 20.5 m

3

(26.8 yd3).

Volvo A40E/A40E FS 6×6 is a three-axle, sprung hauler with articulated frame steering and a load capacity of 39 tonnes

(43.0 sh tons) or 24 m

3

(31.4 yd3).

All machines have 4-wheel drive with 6-wheel drive, which can be engaged and disengaged.

Intended use

The machine is intended to be used under normal conditions for the applications described in the Operator's Manual. If it is used for other purposes or in potentially dangerous environments, for example explosive atmosphere, flammable environment or areas with dust containing asbestos, etc., special safety regulations must 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, four-stroke, diesel engine. The engine is a direct-injection, turbocharged lowemission engine with intercooler.

Electrical system

The machine has four control units (ECUs). The I-ECU (for the instrumentation) is integrated with the display unit, warning lamps and instruments and provides the operator with information via these. The V-ECU (for the machine) receives signals from sensors on the machine and these are sent to the I-ECU. The T-ECU controls the transmission. The E-ECU controls the engine.

Machines with Full Suspension have one further V-ECU.

6

Presentation

Power transmission

The transmission is fully automatic and of the planetary gear type. It has a torque converter with free-wheeling stator and automatic direct drive clutch (lockup) in all gears. The machine has nine forward and three reverse gears.

The dropbox has a differential, which distributes the torque equally between the front and rear axles, thus reducing tyre and road wear as well as fuel consumption. The longitudinal differential is provided with a locking function.

The drive axles are provided with a differential and hub reduction gears of the planetary gear type. All drive axles have a differential lock.

Brakes

Service brakes

The machine is provided with 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, oilcooled, 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 the spring brake type, which acts on the propeller shaft. As the differential lock in the dropbox is engaged at the same time as the parking brake, the latter will act on the two front axles. The spring brake has a separate compressed-air circuit for releasing the brake.

Steering system

The steering system is self-compensating, hydro-mechanical and has a secondary steering function. A ground-dependent pump on the dropbox allows the steering to function even if the engine should stop.

Presentation

7

Cab

The cab has a heating and ventilation system with defrosting for the windows. Air conditioning is available as an option. The cab has two emergency exits, the door and the rear right side window, which must be broken with the hammer kept in the cab, if the window has to be used as an exit.

FOPS and ROPS

The cab is approved as a protective cab according to the standards FOPS and ROPS, see page 188. FOPS is an abbreviation of Falling Object Protective Structure (roof protection) and ROPS is an abbreviation of Roll Over Protective Structure

(rollover protection).

Never carry out any unauthorised alterations to the cab, e.g. lowering the roof height, drilling, welding on brackets for fire extinguisher, radio aerial or other equipment, without first, via a dealer, having discussed the alteration with personnel at the Volvo

Engineering Department. This department will decide whether the alteration may cause the approval to become void.

Modifications

Modifications to this machine including the use of unauthorised attachments, accessories, units or parts that may affect the machine integrity (condition) and/or the ability of the machine to 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 in writing by Volvo Construction Equipment. Volvo Construction

Equipment reserves the right to decline all warranty claims which have arisen because of or can be traced to unauthorised modifications.

Modifications may be considered to be officially approved, if at least one of the following conditions has been met:

1 The attachment, the accessory, the unit or the part has been made or distributed by Volvo Construction Equipment and has been installed according to the factory approved method described in a publication available from Volvo Construction

Equipment; or

2 The modification has been approved in writing by the

Engineering Department for the respective product line at

Volvo Construction Equipment.

Additional structures

All modifications of the basic product may affect its stability. For example this applies when installing body height extension.

If the warranty is to apply, the additional structures must have been approved by Volvo CE.

8

Presentation

Anti-theft device (optional equipment)

An installed anti-theft device makes it more difficult to steel the machine. Volvo CE can supply an anti-theft device as optional equipment. If your machine is not equipped with such a device, look into the possibility of having one installed by your dealer.

Logged machine data

The machine is equipped with a software system that registers and stores various types of information. The information can be transferred to Volvo CE in order to be used for product development purposes and for troubleshooting. The stored information contains among other items travelling speed, fuel consumption and various temperatures. Volvo CE and its authorised workshops will make use of this information.

CareTrack (optional equipment)

The machine can be equipped with CareTrack, a telematics system developed by Volvo Construction Equipment. The system stores machine data, e.g., the machine's position, operating hours, fuel consumption, fuel level, that is available for wireless transmission to a computer. CareTrack is available in different versions, depending on the 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 information, contact a Volvo Construction Equipment dealer.

CareTrack is only available on certain markets. Contact your dealer for more information.

Body height extension for light material

(optional equipment)

It is possible to equip the machine with body height extension in order to transport light material.

The body height extension is attached directly to the ordinary dump body and while it is mounted, only light material may be transported in the dump body.

Full Suspension (FS-system)

A35E FS and A40E FS are equipped with Full Suspension, which is an all-hydraulic suspension system. Machines with Full

Suspension do not have ordinary bogie members, rubber elements and shock absorbers. Instead frame and wheel axles on the machine are connected through six double-acting hydraulic cylinders.

The suspension is adapted according to ground conditions and load, which increases the operator comfort.

L64437A

Presentation

CE marking, EMC directive 9

CE marking, EMC directive

CE marking

(The Declaration of Conformity only applies to machines marketed within the EU/EEA).

This machine is CE marked. This means that when delivered the machine meets the applicable "Essential Health and Safety

Requirements", which are given in EU's so-called Machine Safety

Directive, 98/37/EC.

Any person carrying out changes that affect the safety of the machine, is also responsible for the same.

As proof that the requirements are met, the machine is supplied with an EU Declaration of Conformity, issued by Volvo CE for each separate machine. This EU declaration also covers attachments manufactured by Volvo CE. The documentation is a valuable document, which should be kept safe and retained for at least ten years. The document should always accompany the machine when it is sold.

If the machine is used for other purposes or with other attachments than described in this 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 electromagnetic interference, which may constitute safety risks.

The EU EMC directive about "Electromagnetic compatibility",

2004/108/EC, provides a general description of what demands can be made on the machine out of a safety point of view, where permitted limits have been determined and given according to international standards.

A machine or device which meets the requirements should be CE marked. Our machines have been tested particularly for electromagnetic interference. The CE marking of the machine and the declaration of conformity also cover the EMC directive.

If other electronic equipment is fitted to this machine, the equipment must be CE marked and tested on the machine with regard to electromagnetic interference.

10

Presentation

Communication equipment, installation

A Radio aerial

B Telephone aerial / Two-way radio

Communication equipment, installation

IMPORTANT! All installation of optional communication equipment must be carried out by trained professionals and in accordance with the Volvo CE instructions applicable to the machine.

Protection against electromagnetic interference

This machine has been tested in accordance with EU directive

89/336/EEC governing electromagnetic interference. It is therefore very important that all non-approved electronic accessories, such as communication equipment, should be tested before installation and use, since they can cause interference to the electronic systems of the machine.

Mobile telephones

To obtain the best functionality, mobile telephones should be permanently installed in the electrical system of the machine, with a permanent aerial fixed on the cab and installed as advised by the manufacturer. Note, that if a portable mobile telephone is used, it can constantly transmit information to its base station, even when the telephone 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

Q

Q

The aerial downlead must be of the coaxial cable type. Make sure that the cable is undamaged, that the screen is not split up at the ends, but thoroughly encased in the connector and has a good galvanic contact with the same.

The mating surface between the aerial mounting bracket and the bodywork must be clean metal surfaces, with all dirt and oxide removed. Protect the mating surfaces against corrosion after installation, to maintain good galvanic contact.

Remember to keep interfering cables and those which may suffer from interference apart. Interfering cables are the power supply cables and the aerial cable to the communication equipment. Cables, which may suffer interference, run to and from electronic control units on the machine. Install cable harnesses as close to grounded plate surfaces as possible, as these have a screening effect.

Presentation

Plates and decals 11

Plates and decals

Product plates

The principle diagram below shows the product plates that are located on the machine.

When ordering spare parts and when making enquiries by telephone or correspondence, the model designation and

Product Identification Number (PIN) should be stated.

1 Product plate with Product Identification Number, PIN for the complete machine (shows the model, product and serial numbers, machine weight, engine output and when applicable

CE-approval). The plate is positioned on the left side of the tractor unit frame by the steering joint.

1A: Product plate 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 designation and serial number are positioned on its left side.

6 The decal ”Important engine information” Is positioned at the front end of the engine and on the left side of the tractor unit frame by the steering joint.

7 The engine type designation, part and serial numbers are stamped into both sides of the cylinder block.

8 Cab type, type approval and serial number are positioned on the left side in the cab.

12

Presentation

Plates and decals

Information and warning plates

In the following is shown which warning texts and information texts that can be found on the machine. The machine operator should know and pay attention to warnings and information which are stated on decals and plates. Decals/plates which have disappeared, been damaged, painted over or are no longer legible for other reasons, should be replaced immediately.

The part number (order number) of the respective plates/decals can be found in the Parts Catalogue.

NOTE! The text “WARNING” appears on the warning decals on North America.

1034999

1 Attaching point for lashing. (+ decal for FS-machine)

11026729

1014833

2 Battery disconnect switch

3 Avoid directing water jet against air intakes.

5 WARNING! Do not operate downhill with the gear selector in neutral. Only change gear with the accelerator released.

4 WARNING! The machine must not carry a heavier load than what is stated on the decal (optional equipment on machines with body height extension for light materials).

Volvo Construction Equipment

0

LUFTKOND. FYLLD MED 2.3 -0,1 KG R134a

ÖPPNINGSTRYCK SÄKERHETSVENTIL 38±3 BAR

0

AIR COND. CHARGED WITH 2.3 -0,1 KG R134a

HIGH PRESSURE RELIEF VALVE SETTING 38±3 BAR

A1601500

6 Air conditioning filled with R134a. Opening pressure, safety valve (optional equipment).

7 WARNING! Do not use the overhung tail gate (optional equipment), if there is a risk that it may block the load when tipping. Accidents caused by the machine overturning or the ground giving way can cause injuries and damage to the machine.

8 Emergency exit

1044759

9 WARNING! Risk of crushing – articulated frame steering

1044760

10 WARNING! Do not remain within the working area of a reversing machine.

,22

Presentation

Plates and decals 13

1044761

11 WARNING! Rotating fan.

4948092

13 Brake system under pressure

15 Hydraulic oil

1044762

12 WARNING! Do not lean in under raised dump body, unless it is blocked.

14 Tyre pressure

16 Fuel

A9012200

17 Engine hood

18 Service decal

19

11445056

1020820

WARNING! Only use Volvo coolant VCS – read the

Operator's Manual.

20 Brake cooling oil

1035003

21 Before transporting an FS-machine on another vehicle, lower the machine to bottom position.

A35E

3

5

8

12

18

25

30

50

57

2

3

5

7

11

16

18

31

34

1044669

22 Retarder decal (on page 85 the decal is shown in larger format and for each machine model).

14

Presentation

The USA Federal Clean Air Act


The Federal Clean Air Act Section 203.a (3) prohibits the removal of air pollution control devices or the modification of an EPAcertified non-road engine to a non certified configuration.

The Federal regulations implementing the Clean Air Act for nonroad engines, 40 CFR 89.1003(a)(3)(i), reads as follows:

The following acts and the causing thereof are prohibited:

For a person to remove or render inoperative a device or element of design installed on or in a non-road engine vehicle or equipment in compliance with the regulations under this part prior to its sale and delivery to the ultimate purchaser or for a person 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 engine that would result in an engine that does not match the engine configuration certified to meet the Federal Standards.

Customer Assistance

Volvo Construction Equipment wishes to help assure that the

Emission Control System Warranty is properly administered. In the event that you do not receive the warranty service to which you believe you are entitled under the Emission Control System

Warranty, you should contact the nearest Volvo Construction

Equipment Regional office for assistance.

Presentation

The USA Federal Clean Air Act 15

Normal Non-Road Engine Use

The Maintenance Instructions are based on the assumption that this conventional machine will be used as designated in the

Operator’s Instruction Manual and operated only with the specified fuel and lubrication oils.

Non-Road Engine Maintenance

The non-road engine is of conventional design and any local dealer may perform the necessary non-road engine emission control maintenance defined in this manual.

Volvo recommends that the purchaser use the service program for the non-road engine, known as Preventative Maintenance, including the recommended engine emission control maintenance.

In order to document that the proper regular maintenance has been performed 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 manufacturer's parts and special tools as well as and the latest technical publications. Discuss your servicing and maintenance requirements with your local dealer. He can tailor a maintenance program for your needs.

For regular, scheduled service or maintenance, it is advisable to contact your local dealer in advance to arrange for an appointment to ensure availability of the correct equipment and service technician to work on your machine. In this way you will aid your local dealer in efforts to decrease service time on your machine.

16

Presentation


Preventive Maintenance Program

To retain the dependability, noise level and exhaust emission control performance originally built into your conventional nonroad engine, it is essential that the non-road engine receives periodic service, inspections, adjustments and maintenance.

Fuel system

Fuel Recommendations:

The fuel used must be clean, completely distilled, stable and noncorrosive. Distillation range, cetane level and sulfur content are most important when selecting fuel for optimum combustion and minimum wear.

Engine working conditions and ambient temperature influence the selection of the fuel with respect to cold handling properties and cetane levels.

If the machine is to operate in cold weather 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 ASTM designation: D 975 No. 1D

(C-B) or No. 2D (T-T) with a cetane level above 42 and sulfur content not exceeding 0.05 percent by weight.

Check for fuel leaks (while the engine is running at fast idle):

Q

Visually check unions and hose connections.

Check the condition of fuel hoses for:

Q

Ageing

Q

Q

Q

Cracks

Blisters

Scuffing

Check the condition of the fuel tank:

Q

Drain water condensation.

Q

Q

Q

Check for cracks.

Check for leaks.

Check the mounting.

Check the turbocharger:

Q

Visually check for leaks in the intake hoses and exhaust pipe of the turbocharger.

1



WARNING!

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!

Keep the manual in the cab so that it always is at hand.

2

3

17

1

2

Left instrument panel

Centre instrument panel

3

Right instrument panel

1008392

18


Left instrument panel

Left instrument panel

2

1

A9000301

1

2

3

Rheostat, lights in switches

Rheostat, instrument lighting

Travel lights

6

3

4

5

4

5

6

Front working lights (optional equipment)

Rear working lights (optional equipment)

Keypad for display unit

1 Rheostat, lights in switches

Regulates steplessly the light intensity in all switches.

A9002500

A9002500

2 Rheostat, instrument lighting

Regulates steplessly the light intensity for the centre instrument 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

A9001400

A9001500


Left instrument panel 19

4 Front working lights (optional equipment)


Lower end of switch pressed in = front working lights switched on.

5 Rear working lights (optional equipment)


Lower end of switch pressed in = rear working lights switched on.

A9001600

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.

20


Centre instrument panel


If, during the start-up sequence, any of these lamps do not light up when the ignition key is turned to running position (1), the lamp is faulty or a fault has occurred in the electrical system. This should be dealt with before start.

All lamps should go out when the engine starts, apart from the parking brake lamp, which does not go out until a pressure of

570 kPa (83 psi) has been reached.

6

7

8

9

10

11

12

13

3

4

5

1

2

Preheating connected

Central warning, amber

Central warning, red

Charging faulty

Secondary steering system out of order

Primary steering system out of order

Transmission oil temperature high

Transmission sensor malfunctioning or faulty 21

High beams switched on

22

Direction indicators, tractor unit

23

Direction indicators, trailer unit

24

Engine air filter clogged

25

Is not used

26

14

15

16

17

18

19

20

Coolant temperature high

Engine oil pressure low

Brake system oil pressure low

Parking brake applied

Service brakes applied

Central warning, amber

Display unit

Brake circuit oil pressure in tractor unit

Brake circuit oil pressure in trailer unit

Fuel gauge

Transmission oil temperature

Tachometer

Speedometer/odometer

A9000500


Centre instrument panel 21

1 Preheating connected

Lights when the engine preheating element is connected.

Flashes if the engine coolant temperature is below 0 °C (+32 °F), and the ignition key is in position 1, preheating it is recommended.

2 Central warning (INFO), amber

Lights/flashes in case of the existence of abnormal condition.

Measures may have to be taken depending on the function concerned – investigate the cause at the next stop. See page 37.

3 Central warning (STOP), red

NOTE! If the lamp flashes while operating – stop the machine immediately and investigate the cause.

See page 37.

4 Charging faulty

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 Transmission sensor malfunctioning or faulty

Lights in case of malfunction or faulty sensor in the transmission.

NOTE! Stop the machine, stop the engine and contact workshop authorised by Volvo CE.

9 High beams switched on

Lights when the high beams are on.

10 Direction indicators, tractor unit

Flashes when the direction indicators have been activated.

Indicates that the tractor unit direction indicators are working.

22



11 Direction indicators, trailer unit

Flashes when the direction indicators have been activated.

Indicates that the trailer unit direction indicators are working.

A9000600

12 Engine air filter clogged

Lights if the engine air filter is clogged – replace or clean the filter.

13 Exhaust emission control

Is not used.

14 Coolant temperature high

Lights if engine coolant temperature is too high.

15 Engine oil pressure low

Lights if engine oil pressure is too low.

16 Brake 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 cause at the next stop. See page 37.

20 Display unit

An LCD screen shows many different screens (menus) regarding the condition and state of the machine. Through the display unit you can yourself, with the aid of the keyboard on the left instrument panel, select which menu you want to see, see page 28.


Centre instrument panel 23

21 Brake circuit oil pressure in tractor unit

Shows the hydraulic oil pressure in the tractor unit brake circuit.

22 Brake circuit oil pressure in trailer unit

Shows the hydraulic oil pressure in 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 digital odometer, graduated in km

(miles).

24


Right instrument panel


5

6

7

3

4

1

2

Control lamps

Safety stop, engine

Ignition switch

Cigarette lighter

Unassigned

Delayed stop (optional equipment)

Hazard flashers

8

9

10

11

12

13

Rotating warning beacon (optional equipment)

Electrically heated rear view mirrors (optional equipment)

Electrically heated seat (optional equipment)

Raised engine speed (optional equipment)

Unassigned

FS-system (if the machine is an FS-machine)


Right instrument panel 25

1 Control lamps

A9000100

A9000200

Red central warning (STOP)

NOTE! If the lamp flashes while operating – stop the machine immediately and investigate the cause.

See page 37.

Raised dump body

Lights when the dump body is raised. Does not light when the dump body is in operating position (i.e. when the dump body is resting against the trailer unit frame).

Seat belt reminder

Flashes if the operator is sitting in the seat and forgotten to fasten the seat 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 68.

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 Longitudinal differential lock

3 Transverse differential lock, front bogie axle

4 6-wheel drive

5 Transverse differential lock, rear bogie axle

Machines equipped with ATC, see page 49.

2 Safety stop, engine

The safety stop stops the engine under all circumstances.

26



Delayed stop (count-down in progress)

Delayed stop (count-down completed)

3 Ignition switch

The ignition switch has five positions as shown in the figure.

Turned off position (0)

Radio position (R)

Running position (1)

The engine will stop immediately unless the function "Delayed engine stop" has been activated (optional equipment), see below.

Certain electrical equipment will be supplied with electricity.

The engine will stop if the key is turned from running position (1), unless the function

"Delayed engine stop" has been activated

(optional equipment), see below.

The electronics starts up and goes into running mode.

The anti-theft device (if installed) will be connected.

The safety stop may be connected.

The preheating will be connected.

Preheating position (2)

Starting position (3)

The starter motor will be engaged after a delay of a couple of seconds.

Delayed stop (optional equipment)

When the ignition key is turned from position 1 to position R or 0 and the switch for "Delayed engine stop" (see point 6 below) is switched on, the engine will run for a further three minutes. This time may be changed with VCADS Pro or service display unit

Contronic.

The function will be activated if the following conditions are met:

– gear selector in neutral (N position)

– ignition key in position 0 (turned off)

– the switch is switched on.

If the operator changes his or her mind and wants to continue operating, the ignition key should be turned back to position 1 before the electronics has closed down and the engine stopped.

When the function is activated it is not possible to:

– engage a gear

– change the engine speed (the accelerator pedal is disconnected).

STOP

A9002600

4 Cigarette lighter

The cigarette lighter socket may also be used as a 24 V 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 is switched on.

A9002800

A9002900

A9002400

A9002300

r/min

A9002700


Right instrument panel 27

7 Hazard flashers

NOTE! Must only be used if the machine has to be stopped in a way which constitutes a danger to other road users.

Upper end of switch pressed in = hazard flashers turned off

Lower end of switch pressed in = hazard flashers switched on

8 Rotating warning beacon (optional equipment)

Upper end of switch pressed in = rotating warning beacon switched off

Lower end of switch pressed in = rotating warning beacon switched on

9 Electrically heated rear view mirrors


Upper end of switch pressed in = heating switched off

Lower end of switch pressed 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 provided that the following conditions are met:

– The function operating speed is activated from the service display unit or VCADS Pro.

– No gear engaged (transmission in neutral).

– Lower end of switch pressed in.

12 Unassigned

13 FS-system

Upper end of switch pressed in = system operating position / normal position

Lower end of switch pressed in = system in bottom position

28


Display unit

Display unit

On the display unit, located on the centre instrument panel, is shown starting sequence, component information, operating information, alarm screens and error codes.

When starting the electronics, the screen will display:

Machine hours

When the battery disconnect switch is switched on and the ignition switch is in position 0, the screen shows accumulated number of machine hours. If the machine is equipped with anti-theft device, see page 41.

Machine hours

VOLVO

Screen, starting sequence

A9006400

Initial display

When the ignition switch is turned from position 0 via R to 1, the electronics will start up. Control lamp test is carried out. Initial display is shown on the display unit as an increasing number of rectangles.

The precondition is that the function "Delayed engine stop"

(optional equipment) is deactivated, see page 26.

This sequence takes a few seconds. 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.

Operating information

VOLVO

Screen, closing down sequence

A9006400

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 closed down in a controlled way.

This will be shown on the display unit screen as a reducing number of rectangles, after which the engine stops. This sequence takes a few seconds.

When the ignition switch is turned off, the screen with accumulated number of machine hours will be shown.

If the function "Delayed engine stop" (optional equipment) is activated, see page 26, the engine will not stop until "the delay time" has elapsed. If the ignition key during this time is turned from position 0 to running position 1, the delay is interrupted.


Display unit 29

Keyboard for display unit

With the aid of the keyboard on the left instrument panel the operator may obtain information about the status of the machine, make settings and enter the code for anti-theft device.

1

2 3 4

ENGINE

5

TRANS-

MISSION

6

HYDRAULICS

7

AXLES/

BRAKES

8

ELECTRICAL

SYSTEM

SERVICE

9

SETTINGS

ARROW UP

0

REVERT

SELECT/

ACKNOWLEDGE

ARROW DOWN

Component information

Information about the machine components is obtained by pressing the respective keys. Use the arrow keys for browsing between the images.

Changing the setting of units, 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.

Engine oil

Temperature

Level

Pressure

°C/°F (in case of minus degrees the minus sign will be shown at the first position)

OK / V (low) / – – (incorrect value)


Engine oil

Temperature

Level


% within the measuring range

30


Display unit

Coolant

Temperature

Level



Engine speed

Engine rpm rpm

Setting operating speed

(only shown if the function is available)

Set operating speed

(raised)

To change, see page 35 rpm

Transmission

The screens shown below become available after pressing the transmission key. Change screen with the arrow keys.

Transmission oil

Temperature

Level

Pressure


OK / V low) / (high) / – – (incorrect value)


1012033


Temperature

Level


% within the measuring range

Gear

Position shows the gear selector control position


Display unit 31

Hydraulics

The screen shown below becomes available after pressing the hydraulics key.

Hydraulic oil

Temperature °C/°F (in case of minus degrees the minus sign will be shown at the first position)

OK / V (low) / – – (incorrect value) Level

Via the same screen and browsing downwards it is possible to control the FS-system via the operator display unit, see page 36.

Axles/Brakes

The screen shown below becomes available after pressing the axles/brake key.

Brake cooling oil

Temperature °C/°F (in case of minus degrees the minus sign will be shown at the first position)


The screen shown below becomes available after pressing the electric system key.

Voltage

Current voltage V

Service

The screen shown below becomes available after pressing the service key.

Service

Next service

Time left to next service

250/500/1000/2000 h

Acknowledgement of service, see page 35.

32


Display unit


The screen below will be shown when the engine has been started.


Time 12-display /24-display

Gear position

Outside temperature

N/1/2/3/4/5/6/7/8/9/R1/R2/R3

°C / °F

Activated engine braking

Activated exhaust brake

Activated gear-shift inhibitor

Error code is active

Next Service

The adjacent screen is shown after pressing the arrow-down key.

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).

Operating time after setting to zero

Travelling distance after setting to zero

Fuel consumption after setting to zero

Current values

Fuel consumption (l/h / gal/h)

Travelling

Speed km/h/mph

Gear (N/1/2/3/4/5/6/7/8/9/R1/R2/R3)

Inclination longitudinally %)


Display unit 33

Setting / setting to zero / acknowledgement

The settings below are made with the SETUP key.

Setting display mode

1 Press the SETUP key.

2 Press the select/acknowledge key.

3 Browse with the arrow keys to the required setting. (The setting procedure may at any time be interrupted 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


2 Press the arrow down key to the unit screen.



SI/metric = km, km/h, °C, lit, bar

Non-metric = miles, mph, °F, US gal, psi


34


Display unit

Setting time


2 Press the arrow down key to the time screen.



24-hour display (13:20)

12-hour display (1:20)


6 Cursor is placed by hour. Set the hour(s) with the arrow keys.


8 Cursor is placed by minute. Set the minute(s) with the arrow keys.


Setting date


2 Press the arrow down key to the date screen.



Year-Month-Day

Day-Month-Year

Month-Day-Year


6 Cursor is placed by Year. Set the year with the arrow keys.


8 Cursor is placed by Month. Set the month with the arrow keys.


10 Cursor is placed by Day. Set the day with the arrow keys.



Display unit 35

Setting operating speed (raised speed)


1 Press the engine key.

2 Browse with the arrow down key to the screen for operating speed.



The range for the operating speed is 800–1600 rpm.

Each step represents 50 rpm. (The range can be altered with

VCADS Pro.)


Zero setting cycle counter

1 Press 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.)


1044596

Acknowledging service interval

1 Press the service key.

2 Press the select/acknowledge key. The numerals are shown in reverse image (The acknowledgement may at any time be interrupted with the ESC key.)

3 Acknowledge by first pressing down the service key and then within five seconds pressing down the select/acknowledge key.

4 The next interval (scheduled service) is shown next to the service symbol and the count-down restarts.

36


Display unit

A

B

C

Example of alarm screen

+33

073

-10

102

-33

037

-10

072

+5

042

+23

088

-28

042

+23

088

1044598

D

Forced raising/lowering of FS-system

The hydraulic suspension system Full Suspension can be forcecontrolled manually with the aid of the keypad for the operator display unit. To be able to force-raise the machine, the engine must be running for the hydraulic pump to supply oil and the electronics of the machine must be functional. To be able to force-lower, the engine need not be running, however, the electronics of the machine must be functional.

NOTE! For carrying out service and repairs, the service position, which is especially adapted for machines equipped with Full Suspension, must be used, see page 89.

1 Press on the hydraulics key (A).

2 Press on the arrow down key (B) to the screen "Full

Suspension position display".

3 Press on the select/acknowledge key (C) and then on the service key to access the screen "Forced control".

– Press on the arrow up key (D) to raise. All solenoid valves, which are connected to the 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 latest error codes and alarms

To be able to access the showing of inactive errors, the engine must be turned off. Inactive warning and errors are shown inverted relative to the display setting. If inverted display already has been selected, the inactive errors will be shown in the standard display mode.

The ten last shown alarms / error codes, which then have become inactive, are to be saved on the list.

It the inactive alarms / error codes are shown in reversed chronological order as they were shown to the operator.

A condition for an alarm / error code to take up a new position in the list is that it has not been stored previously during the same 24 hours.

Amber central warning

Red central warning


Display unit 37

Alarm screens

The alarm screen will be shown as long as the error remains.

If amber central warning lights up when the alarm screen is shown, the cause must be investigated at the next stop. The alarm will be repeated next time the engine is started, if it still is active.

Acknowledgement of the alarm is done with the select/ acknowledge key.

If red central warning flashes when the alarm screen is shown, the machine should be stopped and the cause investigated immediately. Values may be checked by using the respective component keys on the keyboard, but the alarm screen returns ten seconds after the last pressing of a key. When required, 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 between different levels, e.g. between orange and red. Reds are always predominant.

Engine

High engine oil temperature Water in fuel

Fuel level low

1012794

Engine overspeeding

Engine, high/low speed

Engine oil level low

Engine air filter clogged Engine oil pressure low Coolant temperature high

Fuel filter clogged

Fuel pressure low

Coolant level low

High crankcase pressure

Intercooler clogged

RPM +

1015455

Request working speed (rpm)

38


Display unit


Low/high system voltage

Alternator, charging function

Delayed stop (count-down in progress)

Engine safety stop

TEST

ECU

ECU in test mode

ECU

1014892


Delayed stop (count-down completed)

Time for service has been exceeded

Reduced performance between

ECUs, information bus (J1708)

VOLVO

A2115900

Starting/stopping electronics

Reduced performance between

ECUs, control bus (J1939)

High speed

km/h

1009264

ECU

CAN2

Service info CAN

ECU

1044642

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

Transmission main filter clogged

ATC

Malfunction ATC

1017661


Display unit 39

Brakes

Brake cooling oil temperature high

Accumulated brake pressure

(servo pressure) low

P

1012063

Parking brake not applied

Low/critical brake cooling oil level Low speed of brake cooling oil pump

Cab

Door is open

Hydraulic system

Seat belt not fastened

Steering pressure from grounddependent / engine-dependent pump low/incorrect

Hydraulic oil level low

Activate float mode

1044650

Hydraulic oil temperature low/high

Tipping control not in holding position, risk of crushing during dump body

Dump body is up

Full Suspension (FS-system)

Full Suspension not in normal position

40


Display unit

Error code screens

The error code screen indicates that a part of the system is out of order. The cause must be investigated at the next stop. When required, contact a workshop authorised by Volvo CE.

Engine

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


Display unit 41

Brakes

Brake system, hydraulics

Hydraulics

Parking Brake

Working hydraulics and servo system

Entering anti-theft code

Brakes, miscellaneous

Anti-theft device (optional equipment)

NOTE! The anti-theft code can be changed with VCADS Pro.

This equipment protects against unauthorised starting of the engine. When the function is activated, the correct four-digit code must be entered to make it possible to start the engine.

The 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 pressing

ESC.

42


Other controls

Controls

Other controls

Controls 43

1 2 3 4 5 6 7

8

3

4

1

2

Controls, steering column

Retarder / exhaust brake

Differential locks and 6-wheel drive

Service socket

7

8

5

6

Steering wheel adjustment

Brake pedal

Accelerator pedal

Control panel

1008417

44

Other controls

Controls

1 Controls, steering column

Headlight dipper

Control upward

Centre position

Headlight flasher

Low beams

Control downward High beams

Horn

The horn sounds when the button is pressed in.

Control, direction indicators

Control forward Right direction indicators

Control rearward Left direction indicators

Windscreen wiper

Position J

Position 0

Intermittent wiper

Neutral position, wiper turned off

Positions I and II Windscreen wiper (two speeds)

Ring pressed in Washer with automatic wiping 3–4 strokes

2 Retarder / exhaust brake

Range A

Range B

Stepless retarder with exhaust brake

Full exhaust brake together with retarder.

3 All differential locks and 6-wheel drive

The differential locks and the 6-wheel drive can be engaged by pressing down the foot control (the lamps in the indicator on the right instrument panel are alight). The differential locks remain engaged for as long as the foot switch is pressed down. See also page 65.

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.

Other controls

Controls 45

5 Steering wheel adjustment

The steering wheel is adjustable as to its inclination and vertical position.

A Control upward The steering wheel may be raised or lowered.

B Control downward The steering wheel can be angled to different positions.

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.

46

Other controls

Controls

8 Control panel

11

1

2

3

4

P

l

12

13

14

6

7

3

4

1

2

5

Unassigned

8

Exhaust braking in accelerator pedal

9

Gear-shift inhibitor

Unassigned

10

The gear selector

Transverse differential lock and 6-wheel drive

(if the machine is equipped with ATC, see page 49)

11

Longitudinal differential lock and 6-wheel drive

(if the machine is equipped with ATC, see page 49)

12

13

14

5

6

7

8

Unassigned

Unassigned

Unassigned

Load and dump brake

Tipping control

Lock-out control for tipping control

Parking brake

1008419

A9001800

A9001900

Other controls

Controls 47

1 Unassigned

2 Exhaust brake / engine braking in accelerator pedal

Upper end of switch pressed in = limited engine braking deactivated

Lower end of switch pressed in = limited engine braking in accelerator pedal activated and the function will be engaged automatically when the accelerator pedal is released. See also page 68.

Gears 1–3

Gear 4

Gear 5

Gears 6–9

0% engine braking

35% engine braking

65% engine braking

100% engine braking

3 Gear-shift inhibitor

Press the switch to engage the gear-shift inhibitor. The switch has a spring return action. See also page 63.

4 Gear selector

NOTE! Never leave the machine with the gear selector in forward or reverse, while the engine is running.

Gear position

Position 1

Position 2

Position 3

Position D

Position N

Position R

1st gear

Automatic shifting between 1st and 2nd gear

Automatic gear shifting between 1st, 2nd and

3rd gear

Aut. shifting between 1st, 2nd, 3rd, 4th, 5th, 6th,

7th, 8th and 9th gear

Neutral position

Aut. shifting between 1st, 2nd and 3rd reverse gear

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.

A9002000

48

Other controls

Controls

11

A9002100

12

13

6 Transverse differential lock, front axle

Upper end of switch pressed in = transverse differential lock disengaged

Lower end of switch pressed in = transverse differential lock engaged

NOTE! Switch missing if machine is equipped with ATC.

7-10 Unassigned

11 Load and dump brake

Press the button to apply the wheel brakes when loading and unloading. This is to save having to use the parking brake unnecessarily.

At the application of the load and dump brake, the transmission is automatically shifted to neutral.

For the application and release of the load and dump brake to take place, a number of conditions have to be met, see page 68.

A9001001

12 Tipping control

The tipping control has four positions:

Position 1

Position 2

Position 3

Position 4

Lowering with hydraulic pressure. This position has a spring return action – must be kept in position by hand.

Floating position, the dump body rests on the trailer unit frame

Holding position, the dump body is kept stationary in the current position

Tipping (dumping) position

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 75.

13 Lock-out control for tipping control

The purpose of lock-out control is to lock the tipping control in holding position.

1

2 l

A

C

P

l

1008427

1016367

Other controls

Controls 49

14 Parking brake

Upper end of switch pressed in = parking brake released

Lower end of switch pressed in = parking brake applied

Application

IMPORTANT! The parking brake should not be applied until the machine is completely stationary.

1 Place the gear selector to neutral.

2 Press in the lower end of the switch.

3 Turn the ignition key to position 0.

If the engine is turned off without the parking brake having first been applied with the switch, the parking brake will be applied automatically.

The application of the parking brake causes the longitudinal differential lock to be engaged automatically (lamp on the right instrument panel lights up). In addition, the transmission becomes locked in neutral – no gear can be selected.

Releasing

Slide down the 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 (Automatic Traction Control)


If the machine is equipped with ATC, the following switches are missing:

1 Longitudinal differential lock and 6-wheel drive

2 Transverse differential lock, front axle

For information on ATC, see page 66.

Power socket

Electrical power for optional equipment can be taken from a 12 V socket (D) on the overhead panel and under the instructor seat in the storage space from a 24 V socket (E). 12 V is only available if the machine is provided with a voltage converter.

D Power socket 12 V

E Power socket 24 V

50

Other controls

Operator comfort

E

D

F

E D

A Instructor seat

B Emergency hammer

C Emergency exit

C

B

A

A

F

A1600700

B

1009292

C

C

D

A

B

E

F

Operator comfort

Operator seat

It is important that the operator seat is adjusted in a correct way in order to provide the best possible comfort.

Mechanical operator seat, adjusting

Backrest inclination

Seat inclination

Seat height

Longitudinal adjustment

Lumbar support

Height limitation with locking function

– full height adjustment = control to the right

– limited height adjustment = control at centre

– transporting position (never use when operating

(travelling)) = lever to the left


Seat with air suspension, adjusting

C

D

A

B

E

F

Backrest inclination

Seat height at front

Seat height at rear

Adjustment according to weight


Lumbar support


Instructor seat

The cab is equipped with a collapsible instructor seat (A). This is intended for an instructor to be able to travel temporarily on the machine in order to instruct or train operators in how to operate and handle the machine in the best possible way.

The instructor must use seat belt.

When an instructor is travelling on the machine, it must be driven with the greatest care (low travelling speed) and on as level ground as possible. The work site should then in advance be levelled and bumps and holes be 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.

Other controls

Operator comfort 51

Seat belt

The seatbelt supplements the safety construction in the cab or the open operator's station and must be used to prevent the operator from t=being thrown from the cab if the machine should roll over.

Using the seatbelt also helps the operator maintain control of the machine in case it rocks violently or gets in to other difficulties.

Q

The seatbelt with associated parts must be inspected at regular intervals. Change the entire seatbelt immediately if it is worn, has loose threads, or if the buckles or roller do not work.

Q

Q

Q

Change the seat belt if the machine has been involved in an accident where the belt has been subjected to high loads or stress.

Change the seatbelt every 3rd regardless of its appearance or condition.

Never make any changes to the belt or its mountings.

Q

Q

Q

The seatbelt is only intended for one adult.

Keep the seatbelt rolled up (retracted) when it is not used.

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 the seat cushion of the instructor's seat to gain access to the storage space.

Emergency hammer

The emergency hammer (B) should be used in emergency situations for:

– breaking the emergency exit's window pane.

– cutting the seatbelt with the knife on the back of the hammer.

Emergency exit

The cab has an emergency exit, the rear right side window (C). If the emergency exit is to be used, the backrest on the instructor seat must be folded down before breaking the window.

IMPORTANT! When the instructor seat is not used, it should be collapsed and folded down.

52

Other controls

Ventilation system


Heating and ventilation system

The control panel for heating and ventilation is positioned under the left instrument panel.

The system is of the integrated type, i.e. filtered fresh air, heated air or cooled air come out of the same nozzles.

General about heating and ventilation

Q

Q

Keep the door closed.

Direct the air flow away from unprotected skin.

Q

Adjust the fan speed until the air flow in the cab feels comfortable.

For settings in different weather conditions, see page 53.

Air conditioning (optional equipment)

Air conditioning will be switched on if:

– The switch is pressed in

– The fan control is at least in position 1.

Air distribution control

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 is equipped with air conditioning.

F 90% fresh air. Used when you want heating (during the cold season) and during defrosting.

Temperature control

Stepless regulation of temperature in cab.

Cold

Warm

Furthest to the left (blue)

Furthest to the right (red)

Fan control

Position 0 Fan switched off.

Position 1 ¼ of full fan speed – used for heating.

Position 2 Half fan speed – used for heating or air conditioning.

Position 3 ¾ of full fan speed – used for air conditioning.

Position 4 Full fan speed – used for defrosting.

Other controls

Ventilation system 53

Ventilation nozzle

Instrument panel

A closed

B open

C directing flow horizontally

D directing flow vertically.

B post (cab corner post)

E closed

F open

G direction of flow.


IMPORTANT! Make sure that the compressor starts up a couple of times during the week so that its seals are lubricated.

For health reasons you should not lower the temperature in the cab more than 6 °C (11 °F) below the outside temperature.

In damp weather

Before switching off the air conditioning, slightly raise the temperature to avoid misting in damp weather.

Short 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 recommendations. Each operator should experiment to achieve the best possible working environment in the cab, i.e. the right temperature without a draught.

Summer

Adjustment for machines with or without air conditioning.

On machines with air conditioning the switch should be pressed in.

Winter

Adjustment for machines with or without air conditioning.

On machines with air conditioning the switch should not be pressed in.

54

Other controls


Defroster

Adjustment for machines with or without air conditioning. On machines with air conditioning the switch should be pressed in.

1

2

A9010900

3

4

5

6

1044899

Dehumidification

The adjustment applies to machines with air conditioning.

The switch for the air conditioning should be pressed in.

The air distribution control should be in position A or B.

Rear vision camera (optional equipment)

The camera at the rear on the machine, together with the monitor in the cab provide the operator with a better view rearward.

The lens on the camera should be cleaned with a damp rag when required.

The rear vision camera is connected when the ignition switch is in position 1, running position.

There is a switch on the monitor for selecting viewing only when reversing or all the time when operating both forward and rearward.

Rear vision system, colour


The rear vision camera, together with the monitor in the cab, provide the operator with a better 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 monitor is on. Halved brightness when the monitor is in stand-by position.

3 CAM-SELECT. Used to adjust the camera.

The menu with different adjustments is shown if the button is pressed and held in approx. 2 seconds, on the condition that the gear selector is not in reverse.

Press the button again to access the desired adjustment.

Hold in the button for approx. 2 seconds to close the menu. It also closes automatically after 10 seconds.

4 Used to adjust volume under "VOICE " in the "INPUT " menu. The buttons are also used to scroll in the menu.

5 DIM. Used to adjust light intensity in the monitor.

6 NOR/BLC. A sensor senses the light around the camera and automatically adjusts the light intensity on the monitor. Do not cover over the sensor.


55


This chapter contains rules which must be followed to make working with the machine safe. However, these rules do not relieve the operator from following laws or other national regulations for traffic safety, industrial safety and labour welfare.

To avoid the risk of accidents, alertness, judgement and respect for applicable safety regulations is a condition.

Running-in instructions

During the first 100 hours, the machine should be operated with a certain amount of care. During the running-in period it is important to check oil and fluid levels often.

After eight hours operation, the wheel nuts should be checktightened. This applies also after changing a wheel, see page 143.

Warranty inspections

In addition to the ordinary maintenance intervals, service actions shall be done at the 100 and 1000 hour warranty inspection, respectively.

These service actions, such as changing oil and other fluids, must carried out by an authorised workshop, if the warranty 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

WARNING!

Some attachments and equipment may affect the operator's visibility. Pay attention to dead angles, where there is no visibility, when operating on work sites and on public roads. When needed, use a signal man.

It may be possible to obtain visibility all around the machine. To achieve acceptable visibility, optional devices can be sued, e.g., warning systems, mirrors, and surveillance cameras (CCTV).

To minimise risks caused by limited visibility, rules and procedures shall be established by the management on the work site. For example:

Q

Q

Q

Q

Make sure that operators and workers on the site have received thorough safety instructions.

Control the traffic flow of machines and other vehicles. If possible, avoid reversing.

Limit the machine's operating area.

Use a signal man to help the operator.

Q

Q

Q

Make available equipment for two-way communication as needed.

Make sure that workers on the site communicate with the operator before approaching the machine.

Use warning signs.

56


The standard ISO 5006 "Earthmoving machinery – Operator’s field of view") covers the operator's visibility around the machine and is intended to be used to measure and evaluate visibility. Compliance with this standard is a requirement in EU-countries and gives improved visibility around the machine.

The machine is tested according to methods and criteria for this standard. The method used to evaluate visibility cannot cover all points regarding operator visibility, but it does give information to determine if optional devices for indirect visibility are needed, e.g., warning systems.

The test was 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 check that there are no obstacles next to the machine.

Q

Q

Check that mirrors and other visibility-enhancing devices are in good condition, clean, and correctly adjusted.

Check that the horn, back-up warning signal, and the rotating beacon (optional equipment) work as intended.

Q

Q

Check if the management has established rules and procedures for the work site.

Always pay attention around the machine to identify any obstacles.

The danger area around an operating machine forms a circle with a radius of least 7 m (23 ft).


Safety rules when operating 57

Safety rules when operating

Operator duties

Q

Q

Q

The machine operator must operate the machine in such a way that the risk of accidents is minimised both for the operator, other road users and persons present at the work site.

The machine operator must be thoroughly familiar with how to operate and maintain the machine and should preferably undergo required training on the machine.

The machine operator must follow the rules and recommendations given in the Operator's Manual, but also pay attention to any statutory and national regulations or specific requirements or risks that apply at the work site.

Q

The machine operator must be thoroughly rested and must never operate the machine under the influence of alcohol, medicine or other drugs.

Q

The machine operator is responsible for the machine's load when operating on public roads as well as during work.

– There must be no risk of the load falling off while operating.

– Refuse any load that is an apparent safety risk.

– Respect the rated load capacity of the machine. Pay attention to the effect of different distances to the centre of gravity and any optional attachments.

Q

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.

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 operator may allow a person to enter the area, but must be careful and operate the machine only when that person can be seen or clearly indicates their whereabouts.

– Prevent any person from being in the cab of a parked vehicle, if there is a risk that the cab can be struck by attachments or falling objects, e.g., rocks or logs. Does not apply if the cab is of adequate strength or protected to handle the object's impact.

Q

Q

The machine operator may only be accompanied by an instructor if there is a specific seat for a passenger.

The following applies for machines equipped with Full suspension:

– Before raising or lowering takes place, the operator must make sure that machine damage or personal injuries are avoided.

NOTE! Risk of crushing.

Q

Always follow local safety regulations and procedures in case of narrow escapes or actual accidents.

58



Q

Q

Accidents

Q

Q

Accidents and also incidents should be reported to the site management immediately.

If possible leave the machine in position.

Only take necessary action so as to reduce the effect of damage, especially personal injuries. Avoid action which may make an investigation more difficult.

Wait for further instructions from the site management.

Q

Q

Q

Q

Q

Q

Machine operator safety

Q

Q

Q

Q

Q

Q

Q

Q

The machine must be operational, i.e. faults which can cause accidents must be rectified.

Suitable clothing for safe handling and hard hat should be worn.

A loose mobile phone should not be used as it may cause interference with important electronics. The mobile phone shall be permanently connected to the machine's electrical system and with a permanent aerial on the outside of the machine, installed according to the manufacturer's instructions.

Always sit in the operator seat when starting the engine/ machine.

Keep your hands away from areas where there is a risk of crushing, e.g. covers, door and window.

Always use the seat belt.

Use steps and handholds when entering or leaving the machine.

Use the three-point grip, i.e. two hands and one foot or two feet and one hand. Always face the machine – do not jump!

The door must be closed when the machine is moving.

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.

The cab is for the protection of the machine operator and it meets the requirements for Roll Over Protective Structures according to the testing standard "ROPS". Therefore, hold firmly onto the steering wheel if the machine should roll over – Do not jump!

The cab is also designed to meet the requirements for falling objects, the weight of which agrees with testing methods according to "FOPS".

The cab has two emergency exits, the door and the right side window.

Only walk or stand on surfaces, which are provided with antislip pads, see page 90.

Do not enter or leave the machine during a thunderstorm.

– If you are outside the machine, keep a good distance away from the machine until the thunderstorm has passed.

– If you are inside the cab, stay there with the machine stationary until the thunderstorm has passed. Do not touch any controls or anything made of metal.

WARNING!

It is forbidden to sit or stand anywhere on the machine, which might impede the operator's ability to manoeuvre the machine.


Safety rules when operating 59

Working within dangerous areas

Working within areas where there are pipes, power lines or cables

Q

Q

It is the duty of the employer to know and mark the position of pipes for gas, water, sewage or power lines or cables on the work site and to inform the operator about these. Failure to do so may have legal consequences. When required, local authorities and/or communication and power companies should be contacted regarding maps, drawings and advice.

Cables and power lines must be protected against damage in a suitable way. Electric cables should, if possible, have the power turned off.

Q

Information about where the gas and water can be turned off should be made available, so that they can be quickly turned off, if they are ruptured.

NOTE! In case of critical closeness to cables, pipes or overhead wires, it may be necessary to take another way.

High voltage overhead power line

Observe 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 supported on fixed insulators).

– 6 m (20 ft) in case of high voltage above 40 kV (line normally carried on suspended insulators).

The distance vertically between machine and overhead 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.

Operating under ground

Q

A specific set of regulations may apply to underground operations and may require special equipment. Talk to your dealer.

Q

Q

Working in confined areas

Q

Check that there is sufficient room for machine and load.

Move slowly.

Drive in the middle of a doorway which is too narrow to allow two machines to meet.

Q

Q

Working near danger areas

Observe great care near marked danger areas.

Do not operate too close to the edge of a quay, ramp etc.

60



Travelling and operating (working) on a public road

As a machine operator you are considered to be a road user and therefore required to know and follow local regulations and national traffic regulations.

It is important to bear in mind that the machine, in comparison with the rest of the traffic, is a slow moving and wide vehicle, 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 or other local conditions, must be used.

Rotating beacon may be used:

– when the vehicle constitutes a hindrance or danger to other traffic

– when working on or by the side of the roadway.


Measures before operating 61

Measures before operating

1 Perform daily service, see page 155. (Make sure that the coolant has required freezing protection in cold weather and that the lubrication oil is intended for use in winter.)

2 Clean/scrape the windows.

3 Check that there are no faulty/loose parts or leaks which can cause 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.

11 Check that there is sufficient fuel in the tank.

After operating

Q

Fill the fuel tank, as this will counteract the formation of condensation water.

62


Starting engine

Starting engine

WARNING!

Starting gas (ether etc.) must not be used at the same time as the preheating element.

WARNING!

Make sure that no person are close to the steering joint when the engine is running. There is a risk of crushing.

IMPORTANT! Run the engine at low idling speed for at least half a minute after start. This is to ensure the lubrication of the turbocharger.

If the machine is equipped with anti-theft device, see page 41.


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 Turn the ignition key to starting position (3). If the engine does not start, turn the key back to the "0" position, before making a new starting attempt.

5 Check that all control and warning lamps are extinguished.

6 Check that the FS-system is in operating position (if your machine is equipped with FS-system).

7 Sound the horn.

8 Hold the machine with the service brakes.

9 Select gear position.

10 Release the parking brake.

11 Increase the engine speed.

At temperatures below 0 °C (+32 °F)

IMPORTANT! Run the engine at low idling speed for at least half a minute after start. This is to ensure the lubrication of the turbocharger.


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 for preheating is flashing, turn the ignition key to preheating position (2). Keep the ignition key in this position until the control lamp is extinguished.

5 Turn the ignition key to starting position (3). If the engine does not start, turn the key back to the "0" position, before making a new starting attempt.

6 Check that all control and warning lamps are extinguished.

7 Check that the FS-system is activated (if your machine is equipped with FS-system).

8 Sound the horn.

9 Hold the machine with the service brakes.

10 Select gear position.


12 Increase the engine speed.

Gear shifting


Gear shifting 63

A Gear selector control

H

L

P

l

1008858

WARNING!

Never leave the machine with the gear selector in forward or reverse, while the engine is running.

The transmission has neutral position, nine forward and three reverse speeds. All with automatic direct drive clutch (lockup).

The gear-shifting system is fully automatic, but the automatic control can be limited by the operator via the gear selector control.

The electronics of the transmission registers the travelling speed of the machine, acceleration and the engine loading. Based on these parameters the electronics controls the gear shifting automatically providing the best comfort, fuel consumption and performance.

Gear position D

– Normal gear position for operating forwards. See also

Overspeed Protection on page 64.

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, that is to say repeated up- and downshifts at short intervals.

The gear-shift inhibitor is disconnected by again pressing the button or when there is a risk of overspeeding.

A Gear-shift inhibitor

64


Gear shifting

Safety functions during gear shifting

The machine is provided with safety functions which protect the engine and transmission via the electronic control unit of the transmission in the event of an operator error.

These functions are:

– The engine can only be started with the gear selector in the neutral position (N position).

– The gear selector control may be moved from the N position to different gear positions, but no gear will be engaged, if the engine speed exceeds 18.3 r/s (1,100 rpm) (stationary machine). If the engine speed is above 1100 rpm it will be lowered automatically to 1100 rpm before a gear is engaged.

– When the parking brake is applied, no gear will be engaged.

– When delayed stop has 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 of travelling direction 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 between 2 km/h and 7 km/h (1.6 and 4.3 mph) the transmission will shift into Neutral.

– If the speed is below 2 km/h (1.6 mph) and the engine speed is below 18.3 r/s (1100 rpm) a new gear may be selected.

Overspeed protection

Q

If there is a risk of the engine overspeeding, an upshift is made to the next higher gear, irrespective of the position of the gear selector and the gear-shift inhibitor.

Right instrument panel

Indicator, differential locks / 6-wheel drive

4-wheel drive without differential locks

Longitudinal differential lock/6-wheel drive


Operating with differential locks 65

Operating with differential locks

WARNING!

We warn especially against the method of trying to traverse slippery ground by force with chains on one drive side only.

This oblique traction power causes extreme wear to the power transmission and you may also lose control of the machine and cause an accident with consequent personal injuries.

NOTE! The differential lock must never be engaged when one of the wheels is spinning.

IMPORTANT! Do not use drive and differential locks on more wheels than what is required by the situation. Incorrect use can cause unnecessary tyre wear, increased fuel consumption and impair the manoeuvrability.

When operating with anti-slip devices (snow chains), the differential locks and the 6-wheel drive should not be engaged.

Operation (without differential locks)

Q

Q

Q

During operation four wheels on the machine are driving and then there is no drive to the rear bogie axle.

All differential locks are disengaged.

No control lamps on the instrument panel are alight.

Longitudinal differential lock / 6-wheel drive

Q

Engagement of the longitudinal differential lock automatically causes the 6-wheel drive to be engaged as well.

Q

Q

Q

The longitudinal differential lock and 6-wheel drive (6x6) is used when operating on soft and slippery ground and on steep inclines.

Engagement and disengagement can be made while operating regardless of travelling speed.

The control lamp for longitudinal differential lock / 6-wheel drive on the instrument panel will be alight.

The control lamp in the switch will be alight.

Q

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

Q

Q

Q

Only use the transverse differential lock on the front axle separately when the ground is very slippery but firm to maintain the best possible steering ability of the machine.

Disengage the lock when operating on firm ground.

The control lamp on the instrument panel for the differential lock on the front axle will be alight.

The control lamp in the switch will be alight.

Transverse differential lock, front axle

66


Operating with differential locks

Longitudinal differential lock / 6-wheel drive + transverse differential lock, front axle

Q

Q

Q

Q

Provides the best possible traction with maintained steering ability on soft and slippery ground.

Disengage the lock when operating on firm ground.

Both the control lamp for the longitudinal differential lock and the control lamp for the differential lock on the front axle, will be alight on the instrument panel.

The control lamp in the switches will be alight.

Longitudinal differential lock / 6-wheel drive and transverse differential lock, front axle

All differential locks / 6-wheel drive

Q

Q

Q

Is used when operating where maximum traction force is required.

The following control lamps on the instrument panel will be alight.

– Longitudinal differential lock/6-wheel drive

– Differential lock, front axle

– Differential lock, bogie axle (front)

– Differential lock, bogie axle (rear)

The control lamp in the switches for the differential locks will be alight, even if the switches are in position 0.

NOTE! The steering ability of the machine is reduced.

For engagement and disengagement of the differential locks, see page 47.

All differential locks / 6-wheel drive

ATC (Automatic Traction Control)


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

Q

Automatic mode.

All differential locks and 6-wheel drive are engaged with the foot control.

Automatic mode

Used for all types of operating conditions.

The machine senses wheel speed and steering angle, and the longitudinal differential lock and 6-wheel drive are engaged automatically,independent of each other.

No control lights for differential locks or 6-wheel drive are lit on the instrument panel at engagement or disengagement.

All differential locks and 6-wheel drive

Is used when operating where maximum traction force is required.

Control lights for all differential locks and 6-wheel drive are lit on the instrument panel.

NOTE! The steering ability of the machine is reduced.

A Control lamp (red) engine-dependent pump (primary steering system)

B Control lamp (amber) grounddependent pump (secondary steering system)


Steering 67

Steering

The steering system is a self-compensating, hydro-mechanical system and provided with a secondary steering function via a ground-dependent pump positioned on the dropbox. This ensures steering down to approx. 3 km/h (1.9 mph) even if the engine should stop.

During all forward operation the control lamp (red) for enginedependent pumps and the control lamp (amber) for grounddependent pump (the secondary steering) should be extinguished.

If the red lamp (A) for the engine-dependent pumps is alight:

The hydraulic pumps have stopped functioning (e.g. the engine has stopped). The steering will work down to approx. 3 km/h

(1.9 mph). The steering pressure is obtained from the grounddependent pump when operating forward.

If the amber lamp (B) for the ground-dependent pump is alight:

The hydraulic pump has stopped functioning. 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-dependent pump). This means that the secondary steering works down to approx. 3 km/h (1.9 mph) when operating forward.

Testing the secondary steering system

Test the secondary steering system every 2000 hours.

Run the machine on a road where there is no other traffic, stop the engine by pressing in the emergency stop when the machine is moving at approx. 10 km/h (6 mph). The steering should function down to a speed of approx. 3 km/h (1.9 mph).

NOTE! The pressure in the brake system should be at maximum level before testing.

68


Braking

Braking

Service brakes

A Service brakes

B Parking brake

H

L

A Switch, engine braking

D Switch, load and dump brake

1008859

1008861

B

WARNING!

In case of a faulty brakes, stop the machine immediately and contact a workshop authorised by Volvo CE for action to be taken.

The service brakes are divided into two separate circuits. If a fault arises in one of the circuits, the machine can still be braked with the intact circuit.

If brake action is lost in both brake circuits, apply the exhaust brake and the parking brake and stop the machine.

Parking brake

The parking brake should not be applied until the machine is completely stationary.

Application and release, see page 49.

The parking brake is self adjusting (no after-adjustment is necessary).

NOTE! When the parking brake is applied, it is not possible to engage a gear.

Emergency brake

Q

Q

In an emergency situation the parking brake may be used as an emergency brake (if the parking brake is used as an emergency brake, the load and dump brake will be engaged automatically if the speed is above 2 km/h (1 mph)).

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 accelerator pedal is pressed down

– the switch is switched off.

Load and dump brake

The load and dump brake activates the service brakes and puts the transmission in neutral. This is to facilitate loading and dumping.

This function can only be activated at speeds below 5 km/h (3.1 mph).

The function is deactivated when the gear selector is moved from neutral position.


Stopping machine 69

Stopping machine

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 leaving. Do not jump!

1 Release the accelerator pedal.

2 Brake and put the gear selector control in neutral, when the machine is stationary.

3 Apply the parking brake.

4 Let the engine 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).

70


Parking

A Battery disconnect switch

Parking

1 If possible, place the machine on level ground. If this is not possible, block the wheels so that the machine cannot start rolling.

2 Make sure that the dump body is lowered or made safe. Avoid parking a loaded machine.

3 Check that switches and controls are in the "off" position or in neutral.


5 Close windows, remove the ignition key and lock the door to the cab.

6 Turn off the battery disconnect switch (A), which is positioned on the left side of the cab under the entry step.

Long-term parking

1 Carry out the measures as described above. Remember that the ground on which the machine is to stand may shift depending on the weather. Therefore take suitable action.

2 Lower the FS-system right down, if the machine is equipped with an FS-system.

3 Wash the machine and touch up the paint finish to avoid rusting.

4 Rustproof exposed 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 batteries will be discharged.

Remember that the risk of theft and break-in can be minimised if one:

– removes the ignition key when the machine is left unattended

– locks doors and covers after the end of the working shift

– turns off the current with the battery disconnect switch and removes the handle for the switch

– avoids parking the machine in places with high risk of theft, break-ins and malicious damage

– chains the machine to an immobile object.

It is easier to identify stolen machines if PIN number or registration number is etched onto the windows.

After the long-term parking check

– all oil and fluid levels

– all belt tensions

– tyre pressure

– air cleaner.

– battery status.


What to do if the machine gets stuck 71

What to do if the machine gets stuck

Step 1 (by operating in zigzag / ”duck's waddle”)

1 Engage all differential locks with the foot button.

2 Keep an even engine speed and avoid wheel spin.

3 Steer alternately full lock to the right and full lock to the left.

When you have reached full lock in one direction, continue operating in that direction until the machine is just about to stop, before turning to full lock in the other direction.

If the machine becomes stationary after 3–4 turns, or if it sinks deeper, abort and proceed to step 2.

Step 2 (by rocking loose)

1 Release the accelerator to stop the wheels from spinning.

2 Engage the differential locks.

3 Select gear position 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 machine during the dumping operation.

3 Remove the dumped material with the aid of the supporting machine.

4 Lower the dump body.

5 Allow the assisting machine to lift and push at the rear of the dump body at the same time as the hauler is operated according to step 1 until it is free.

Step 4

Getting unstuck with towing assistance

If the hauler has not bogged down, but the wheels are simply spinning, it can be towed with the aid of a tow bar, wire rope or chain connected to the towing eyes or pushed by another machine.

See also page 72.

72


Recovering/towing


Q

Q

Q

WARNING!

The greatest care must be taken in connection with towing to avoid serious injury.

Before taking any steps in preparation for recovering or towing, the parking brake must be applied and the wheels

blocked to prevent the machine from rolling.

If the engine cannot be started, the brake and steering functions will be limited. In this case, towing should be restricted to emergencies only and over the shortest possible distance by knowledgeable personnel (see under Towing). If possible, transport the machine on a trailer.

During recovering / towing the engine should be running, if possible, to provide braking and steering.

Recovering

Q

Use a towbar, wire rope or chain connected to the towing eyes at the front or rear on the machine to tow the machine to a suitable location or passable road.

Towing

Q

Q

Q

If the machine after recovering must be towed to a workshop, use a towbar or wire rope connected to the front towing eyes.

If there are no brakes on the machine to be towed, a towbar must always be used.

The vehicle or machine which does the towing, must be at least as heavy as the towed machine, and have sufficient engine and braking capacity to be able to pull and stop both machines on any uphill or downhill slope.

Q

Q

Towing should always be done over the shortest possible distance.

Highest travelling speed during all circumstances is 10 km/h

(6 mph).

NOTE! It is not possible to start the engine by towing.

A Output propeller shaft

1034964

B Filler valve

B


Recovering/towing 73

Case 1 (with engine running)

The gear selector should be in neutral and the parking brake in running position. The machine can be towed 10 km (6 miles) without taking special precautions.

Case 2 (with engine not running)

As the transmission does not receive any lubrication when the engine is not running, the propeller shaft between transmission and dropbox must be removed. In that way lubrication to the dropbox is maintained at the same time as the machine can be steered.

Removing propeller shaft

1 Place the machine in service position, see page 89.

2 Block the wheels so that the machine cannot start rolling and then release all brakes.


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 machine.

The filler valve is positioned to the left behind the cab.

After recovering / towing

The following safety measures should be taken before the towbar, wire rope or chain is disconnected after recovering / towing:

1 Place the machine on level ground.


3 Block the wheels to prevent the machine from rolling.

74



Manual release of parking brake

A Jacking bolt

B Cover

C Cylinder housing

WARNING!

After the parking brake has been released manually it will not work. The machine must only be towed, if it is connected to the towing vehicle by a towbar.

If the parking brake cannot be released with the switch because of insufficient compressed air, the brake can be released manually.

Proceed as follows:

1 Block the wheels or prevent the machine from rolling in another way.

2 Remove the jacking bolt (A) from the storage location.

3 Remove cover (B) from the cylinder housing.

4 Insert the jacking bolt in the cylinder housing (C) and turn the jacking bolt ¼ of a turn clockwise to lock it.

5 Release the parking brake by screwing in the jacking bolt clockwise until the brake pads no longer are applied.

NOTE! If the machine is left without 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 brake with the switch on the control panel.

4 Screw the jacking bolt counter-clockwise until it is loose.

5 Install the cover on the cylinder housing and reinstall the jacking bolt in its retainer.

6 Then check the function of the parking brake.

Tipping control

1 Lowering with pressure

2 Floating position

3 Holding position

4 Tipping (dumping) position)


Tipping 75

Tipping

When dumping, the following points should be observed:

– Steer the machine so that it is straight and with the trailer unit on level ground.

– Ensure that no persons are near the machine.

If conditions permit, dumping may be carried out while moving.

Tipping control

Dump body lowered by hydraulic pressure = position 1

This position is used when the dump body is in such a position that it will not lower under its own weight.

Move the control to position 2 when the dump body begins to lower under its own weight.

Floating position = position 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 interrupting the tipping or lowering movements. The dump body stops in the current position.

Tipping (dumping) position = position 4

Is used when tipping (dumping). Keep the tipping control in this position. Reduce the engine speed before the dump body reaches its top position.

76


Dump body, emergency lowering

V1061978

The position of the operator during emergency lowering

Dump body, emergency lowering

The operation of the dump body, i.e. tipping and lowering, is controlled with servo pressure.

If the engine should stop with the dump body in the raised position and the starter motor, for some reason, does not work, there will be no servo pressure for operating the tipping valve and the dump body must be lowered manually. The emergency lowering bolt is located on the steering and tipping valve.

A Jam nut

B Emergency-lowering screw

C Allen key

1034782

WARNING!

Use the greatest caution when carrying out emergency lowering, as it is not possible to place the machine in service position.

NOTE! Emergency lowering must be carried out from outside the machine where the dump body is in full view of the operator during the entire lowering.

It is possible to emergency-lower the dump body in the following way:

The steering and tipping valve is located under the cab.

1 From outside 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 pressure).

2 This will cause the dump body to slowly lower unless it is near its top position and the machine is leaning backwards. In this case the dump body needs aid to lower through the action of an excavator or wheel loader, which lifts at rear edge of the dump body.

3 Reset the screw to its original position.


Full Suspension, emergency lowering 77

Full Suspension, emergency lowering

The control of the FS-system, i.e. raising and lowering, is by way of hydraulics. If the engine should stop with the system in the raised position and the starter motor, for 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 a workshop authorised by Volvo CE for aid with emergency lowering.

78


Transporting the machine


A

A Steering joint lock

1031118

1034999

WARNING!

If the machine is driven across from a loading dock onto the platform of a truck or trailer, make sure that this vehicle is securely braked, i.e. the wheels blocked and that there is no risk that the vehicle will tip or tilt in a dangerous way as the machine is driven across.

Steering joint lock

During service work, lifting and transporting the machine on another vehicle, the steering joint should be locked.

1 Place the machine so that it is straight and turn off the engine.

2 Remove the pin from the transporting position lug and swing the joint lock (A) over to the locked position.

3 Install and secure the pin.

WARNING!

Make sure that no person are close to the steering joint when the engine is running. There is risk of injuries by crushing.

Transporting on another vehicle

Q

Q

Q

If the machine is driven up onto another vehicle, the steering joint must not be locked. Lock the steering joint when the machine is in position on the transporting vehicle.

The transporting vehicle must be securely braked and the wheels blocked.

If the machine is lifted, however, the steering joint should be locked.

Lashing the machine for transportation

Q

Q

Q

Lock the steering joint with the steering joint lock when the machine is in position on the transporting vehicle.

Apply the parking brake and block the wheels.

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

Q

In addition to this, follow national regulations.

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 is equipped with an FS-system, the system must always be in the lowered position during all service and lifting and when transporting the machine.

IMPORTANT! If the machine is equipped with an FS-system, the lashing must be loosened before the FS-system is activated. Great risk of machine damage and personal injury.


Transporting the machine 79

Lifting machine

The lifting tool is optional equipment to be used for lifting the machine. They are intended for a machine weight of max.

33500 kg (A35E/A35E FS) / 39000 kg (A40E/A40E FS).

IMPORTANT! If the machine is equipped with FS-system, it must be lowered right down before lifting is carried out.

WARNING!

Never remain under the machine when it is suspended in the air.

WARNING!

Do not lift the machine using the eyes on the dump body.

Lifting tool, (optional equipment)

WARNING!

The lifting tool must only be installed together with the special nuts supplied together with the tool, otherwise the tool may loosen causing serious damage. When removing the tool, the ordinary wheel nuts must be reinstalled.

Q

Q

Q

Q

Q

Q

Q

It is important that correct lifting tools and nuts are used.

The combination of rim and tyres determines which tool and nuts are to be used, see below.

It is important that the lifting tool is installed in a correct way.

The lifting tool should only be installed on the machine for when lifting and transporting. Remove the tool after use.

The nuts, which belong to the lifting tool, should preferably be stored on the tool, when they are not used.

The ordinary wheel nuts should not be stored on the tool when the tool is installed on the machine.

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 the lifting tool itself.

Lifting tool

Part No. 15011655

Nut

Part No. 11193630

Tightening torque for nuts for lifting tool, 200 Nm (148 lbf ft).

80



1 Place the machine on level ground.

2 The engine must be turned off and the battery disconnect switch turned off.

3 Lock the steering joint with the steering joint lock.

1031118

4 Install the lifting tool to front axle and the front bogie axle and tighten the nuts crosswise to 200 Nm (148 lbf ft).

m in

.

8

,5 m

V1054697

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).

V1054698

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.

Storing lifting tool

V1054702


81


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.

82


Whole body vibrations


Whole-body vibration emissions on construction machinery are affected by a number of factors, such as the working mode, ground conditions, speed, etc.

To a large extent the operator can influence the actual vibration levels, because the operator controls the speed of the machine, its working mode, the travel path, etc.

Therefore, this may result in several different vibration levels for the same type of machine. For cab specifications, see page 188.

Guidelines for reducing vibration levels on earthmoving machines

Q

Q

Q

Q

Q

Q

Use the proper type and size of machine, with optional equipment and attachments for a certain application.

Make sure that the ground is kept in good condition.

– Remove larger stones and obstacles.

– Fill in any ditches and holes.

– Provide equipment and schedule time for maintaining terrain conditions.

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.

Maintain machines according to the manufacturer's recommendations.

– Tire pressures.

– Brake and steering systems.

– Controls, hydraulic system and linkages.

Make sure that the operator seat is maintained and correctly adjusted:

– Adjust the seat and its suspension according to the operator weight and height.

– Inspect and maintain the operator seat suspension and adjustment mechanism.

– Use the seat belt and adjust it correctly.

Minimise vibrations during long work cycle or long distance travelling.

– Transport machines when there are long distances between work sites.


Whole body vibrations 83

Back pain associated with whole-body vibrations may be caused by other risk 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.

84


Transport operation

Transport operation

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 sideways.

Therefore, great care must be exercised when operating the machine. Avoid operating fast round bends, on uneven ground and on downhills.

When operating through a bend at high speed, you must always bear in mind that there is a risk of overturning. The risk of overturning increases when the centre of gravity of the load is high or displaced to one side or if the bends are sharp, cambered the wrong way or the surface is slippery.

Q

Q

Q

Q

Q

Q

Q

For all operation on roads with moderate inclines select gear position D. The machine will then shift gears automatically depending on need for traction power.

Utilise the maximum speed of the machine with sound judgement.

Always adapt the speed to the road conditions and the traffic situation in order to operate safely and comfortably.

Pay attention to the trailer unit's movements while operating.

On no account must there be any risk of part of the load falling off when transporting.

Do not forget to disengage all differential locks, if you are operating on a good road (firm surface).

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.

A Retarder pedal

1008862


Operating on inclines 85

Operating on inclines

Uphill operation

The automatic transmission normally makes sure that the correct tractive force is provided in proportion to the incline.

Under certain conditions, the transmission may start “gear hunting”. This means that the transmission changes up and down between two gears at short intervals.

The gear-shift hunting is caused by that there is not sufficient power for operating in the higher gear, but enough for upshifting from the lower gear.

It is possible to prevent gear-shift hunting in two ways:

1 Select the next lower gear.

or

2 Activate the gear-shift inhibitor function with the switch on the control panel.

Always engage the longitudinal differential lock / 6-wheel drive when operating in difficult terrain, see page 86.

Downhill operation

A35E

3

5

8

12

18

25

30

50

57

2

3

5

7

11

16

18

31

34

1044669

A35E

Max. permitted speed when operating downhill

A40E

3

6

8

12

18

27

43

50

57

2

4

5

8

11

17

27

31

35

1044670

A40E

Max. permitted speed when operating downhill

Q

Q

Q

WARNING!

Do not permit engine revs above 35 r/s (2100 rpm) when operating downhill.

When operating down a steep incline with a full load, it may happen that the exhaust brake and the engine braking function together do not provide sufficient retardation and this leads to an increasing travelling speed. If this happens, also the service brakes must be used.

The machine must not be allowed to roll with the gear lever in neutral.

To avoid unnecessary stress to the transmission, 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 loose 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.

86


Off-road operation

Off-road operation

Different types of terrain require different operating techniques.

Check out the ground beforehand, 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.


Loading 87

Loading

1 Place the hauler in the indicated place. Make use of the advantages of the articulated steering and place the machine at the best angle for loading. Use the rear view mirrors and keep eye contact with the loader operator while reversing.

2 Apply the load and dump brake, see page 48.

3 Always make sure that the tipping control is in ”Floating position” when loading. If this is not the case, the whole load will be resting on the tipping cylinders instead of on the frame.

NOTE! Remember that it is you as the operator of the hauler, who is responsible for the size and weight of the load, see page 57.

Before moving off, make sure that no part of the load, e.g. stumps or stones, can fall off and cause injury or damage. Protruding objects must be removed.

Body height extension (optional equipment)

Machines equipped 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 haulers have very good off-road characteristics, which are often utilised to shorten transporting distance and time.

You must follow indicated transporting paths. If you consider that it is possible to take cross-country shortcuts, or go off the road to facilitate meeting oncoming traffic, you must always obtain the management's permission to do so.

The condition of the transporting road is of great importance to the capacity of the hauler. If the transporting road is long and poorly maintained, try to influence the management into maintaining the road at a better standard, so that you can keep a higher speed, which means a higher capacity.

88


Dumping load

Dumping load

WARNING!

For all dumping, check out the firmness and inclination of the ground. When dumping over an edge, do not reverse

further out than the rear axle is still on firm ground. Check

the firmness of the edge.

The way of dumping depends on the condition of the load.

Method A: This is the quickest way to unload where the site is large and the load is to be bulldozed over an edge.

Method B: Reverse out as close to the edge as possible so that most of the load falls over the edge. The saving is that one avoids having a dozer on the unloading site.

Always watch the rear view mirrors while reversing. Do not stop until the wheels on the rear axle reach the edge. Avoid driving in the same tracks to reduce the risk of getting stuck. Save some of the load and deposit it on the edge.

Method C: When dumping in a heap: reverse up and dump as high up as possible in the heap.

Method D: If a road embankment or a slightly elevated surface is to be built up, make use of the machine's off-road manoeuvrability 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 lever backwards to dumping position and increase the engine speed.

– Reduce the engine speed just before the dump body reaches its top position.

– Move the hauler forward a few metres, before you lower the dump body. Move the tipping control to floating position.

Never operate further than necessary with the dump body raised. Never make steering movements with the hauler, if the entire load has got stuck and the dump body is raised.


Service position 89


Service position

WARNING!

If work has to be carried out on the machine before it has cooled down, care must be observed with regard to hot liquids and hot machine parts – risk of burns.

IMPORTANT! If the machine is equipped with FS-system, make sure that the system is in the lowered position before beginning any service work.

Before you begin any service work, the machine should be placed on level ground and prepared for service as shown below:

1 Lock the steering joint with the steering joint lock. Lower the dump body onto the frame.

For service with the dump body up, secure with the dump body lock or the dump body support, see page 94. Lock the dump lever with the lock-out control, see page 48.

2 Let the machine cool.

3 Carefully release 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.


5 A yellow-black warning label or a red flag should be attached to the steering wheel while service is being done.

6 Stop the engine and take out the ignition key (does not apply when checking the oil in the transmission).

7 Block the wheels in a suitable way (with, for example, wedges).

NOTE! For work on and with the FS-system, contact a workshop authorised by Volvo CE.

90

Slip protection


Before service, read

L64527A

Before service, read

Prevent personal injuries

Q

Q

Q

Q

Q

Q

Read the Operator's Manual before beginning any service work. It is also important to read and follow the information and instructions given on plates and decals.

Do not wear loose-fitting clothes or jewellery, which may catch and lead to injury.

Always wear a hard hat, safety glasses, gloves, protective shoes and other protective articles when the work so requires.

Make sure that there is sufficient ventilation when starting the engine indoors.

Do not stand in front of or behind the machine while the engine is running.

For service work with the dump body up, secure with the dump body lock or the dump body support, see page 94. Lock the dump lever with the lock-out control.

IMPORTANT! Always lean in under the dump body from one side when the dump body lock is to be locked or unlocked.

Q

Q

Stop the engine before opening engine hood, radiator casings and similar covers.

When the engine has been stopped, there is still accumulated 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

Q

Q

When looking for possible leaks, use a piece of paper or stiff board, not your hand.

Make sure that stepping surfaces, handholds and slip protected surfaces are free from oil, diesel fuel, dirt and ice.

Never step on surfaces on the machine that are not intended for this.

It is important that correct tools and equipment are used.

Defective tools or defective equipment must be repaired or replaced.

Prevent machine damage

Q

Q

Q

Q

When lifting or supporting the machine or parts of the machine, make sure that the equipment you are using has sufficient lifting capacity.

Lifting devices, tools, working methods, lubricants and spare parts prescribed in the Operator's Manual must be used. Volvo

CE will not accept any responsibility if this is not followed.

Make sure that no tools or other objects, which may cause damage, are left inside or on the machine.

Release the pressure in the hydraulic system before beginning service work.


Before service, read 91

Q

Q

Q

Q

Q

Never adjust a reducing valve to a higher pressure than what is recommended by the manufacturer.

Machines, which are used within a contaminated or in any other way unhealthy area, must be equipped for such work. Special safety regulations apply when servicing such a machine.

When installing two-way radio, mobile telephone or similar equipment, the installation must be carried out according to the instructions from the manufacturer in order to eliminate interference with the electronic system and components intended for the function of the machine, see page 10.

Measures during electric welding, see page 124.

Make sure that all covers on the machine are in position before starting the engine and putting the machine to work.

Prevent environmental influence

Be conscious of the environment when carrying 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

Q

Q

Q

When draining, oils and liquids must be collected in suitable vessels and steps taken to avoid spillage.

Used filters must be drained of all liquid before they are passed on as waste. Used filters from machines which work in environments with asbestos or other dangerous dust, must be placed in the bag supplied with the new filter.

Batteries contain substances dangerous to the environment and health. Used batteries must therefore be handled as waste dangerous to the environment.

Consumables, e.g. used rags, gloves and bottles may also be contaminated with oils and liquids dangerous to the environment and must in that case be treated as waste dangerous to the environment.

92

A Chain

B Lower bolt

C Upper bolt

D Pin


Preparations before service


Guard plates, lowering

For certain service work it is necessary to hinge down or remove the guard plates.

Place the machine in service position, see page 89.

Front guard plate

1 Remove the bolts 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 same way with the other guard plate.

A

1031121


Preparations before service 93

Engine hood

Opening

1 Press in catches (A).

2 Let down the front grille (a gas spring takes up its weight).

3 Turn the hydraulic pump valve (B) to the downward position with a socket wrench placed by the hydraulic pump. Turn clockwise to end position.

Manual opening

4 Take out extension (C) which is placed in the front grille and join it up with the socket wrench.

5 Engage socket wrench (D) with the pump and begin to pump until the engine hood has reached its upper end position.

Electric opening (optional equipment)

6 Place the socket wrench on switch (E) and turn clockwise to end position. The switch has a spring return action.

7 Keep the socket wrench in this position. Release the socket wrench when the engine hood has 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 counterclockwise 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 lower end position.

Electric lowering (optional equipment)

11 Place the socket wrench on switch (E) and turn clockwise to end position. The switch has a spring return action.

12 Keep the socket wrench in this position. Release the socket wrench when the engine hood has reached its lower end position.

After lowering

1 Put the socket wrench and extension back in their storage position.

2 Hinge up the front grille.

3 Check that the catches for the front grille engage properly.

Hydraulic pump

A Catches, front grille

B Valve

C Socket wrench with extension

D Switch

94



Steering joint lock

A Steering joint lock

A

1031118

WARNING!

The steering joint lock must be in the locked position during all work on the steering joint.

1 Remove the pin from the transporting position lug and swing the joint lock (A) over to the locked position.

2 Install and secure the pin.

NOTE! The steering joint must not be locked when operating the machine.

Dump body lock

WARNING!

When working with a raised dump body, the dump body must be secured with the dump body lock or the dump body support.

Secure the dump body as follows:

1 Tip up the dump body to max. tipping (dumping) angle.

2 Lock the dump body with the dump body lock (C) or lower the dump body down against a dump body support.

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.

C

B Lock-out control for tipping control

C Dump body lock

1031122


Fire protection 95

Fire protection

WARNING!

If a machine is used in an environment, where the risk of fire is particularly high, e.g. in explosive environment, special equipment is required.

There is always a risk of fire. Find out which type fire extinguisher that is used at your place of work and how it is used.

If the machine is to be provided with a hand-held fire extinguisher, it should be of the ABE (in North America ABC) type. The designation ABE means that it is possible to extinguish fires in both solid and liquid organic material and that the fire extinguishing compound does not conduct electricity. The efficiency class I means that the time the extinguisher is effective must not be less than 8 seconds, class II at least 11 seconds and class III at least

15 seconds.

A hand-held fire extinguisher ABE I normally corresponds to an extinguishing powder content of 4 kg (8.8 lb) (EN-grade 13A89BC), the EN 3-1995 standard, parts 1, 2, 4 and 5.

Preventive fire protection

Q

Q

Q

Q

Do not smoke and make sure that there is no open flame near the machine when filling with fuel or when the fuel system has been opened and in contact with the surrounding air.

Diesel fuel is flammable and must not be used for cleaning. Use car care products 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

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.

Check daily that the machine and the equipment, e.g. underbody plates are free from dust and oil. In addition to that the risk of fire is reduced it will be easier to detect faulty or loose components.

NOTE! Observe great care when using high-pressure wash when cleaning. Electrical components and electrical cables may be damaged even at moderately high pressure and temperature. Protect electrical leads in an appropriate way.

Q

Q

Take extra care when cleaning a machine that is used in a firesensitive environment, e.g. sawmill and refuse dumps. The risk of spontaneous combustion can be further reduced by, for example, installing insulation around the silencer guard.

It is important that the fire extinguisher is maintained so that it works when it is required.

96


Fire protection

Q

Q

Check that fuel lines, hydraulic and brake hoses and electrical cables have not been damaged by chafing or are not in danger of being damaged in that way because of incorrect installation or clamping. This applies particularly to unfused cables, which are red and marked R (B+) and routed:

– between the batteries

– between battery and starter motor

– between alternator and starter motor

Electrical cables must not lie directly against oil or fuel lines.

Do not weld or grind on components which are filled with flammable liquids, e.g. tanks and hydraulic pipes. Exercise care with such work in the proximity of such places. A fire extinguisher should be kept near to hand.

Actions in case of fire

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 machine and the danger area.

Actions after fire

When handling a machine which has been damaged by fire or been exposed to other intense heat, the following protective steps must under all circumstances be taken:

Q

Use protective goggles and thick protective gloves made of rubber.

Q

Q

Never touch burnt components with your bare hands to avoid contact with melted polymers. First wash thoroughly with plenty of lime water (a solution of calcium hydroxide, i.e. slaked lime in water).

Handling of heated fluorocarbon rubber, see page 98.


Handling hazardous substances 97

Handling hazardous substances

Heated paint

WARNING!

All paint decomposes when heated and forms compounds, which may cause irritation and in case of prolonged or

repeated exposure be very health-impairing.

When heated, paint gives off poisonous gases. Therefore, the paint must be removed from an area of at least 10 cm (4 in) from the spot where welding, grinding or gas cutting is to be carried out.

In addition to the health hazard, the weld will be of inferior quality and strength, which, in the future, may cause the weld to break.

Methods and precautionary measures when removing paint

Q

Q

Blasting

– use respirator and protective goggles

Paint remover or other chemicals

– use a portable air extractor, respirator and protective gloves

Grinding machine

Q

– 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 never be burned when scrapped.

If gas cutting or welding is to be carried out near such materials, the following safety instructions must be followed:

– Protect the material from heat.

– Use protective gloves, protective goggles and an approved respirator.

98


Handling hazardous substances

Fluorocarbon rubber which has been heated

WARNING!

Certain seals, which are intended to withstand high operating temperatures, e.g. in engines, control valves, hydraulic motors and pumps, may be made from fluorocarbon rubber. When heated to high temperatures, fluorocarbon rubber decomposes to hydrogen fluoride and hydrofluoric acid, which is very corrosive to skin and respiratory tracts.

When handling a machine which has been damaged by fire or been exposed to other intense heat, the following protective steps must under all circumstances be taken:

Q

Q

Q

Use thick, gloves made of rubber and wear protective goggles.

Discard gloves, rags etc. that been in contact with heated fluorocarbon rubber after having first washed them in lime water (a solution by calcium hydroxide, i.e. slaked lime in water).

The area around a part that has been very hot and which may be made of fluorocarbon rubber must be decontaminated through thorough and ample washing with lime water.

Q

Q

Q

Q

As a precautionary measure all seals (O-rings and other oil seals) must be handled as if they were made from fluorocarbon rubber.

The hydrofluoric acid may remain on the machine parts for several years after a fire.

If swelling, redness or a burning sensation occurs and one suspects that the cause may be contact with heated fluorocarbon rubber contact a medical doctor immediately.

Symptoms may not appear until after several hours without any previous warning.

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.

WARNING!

The refrigerant R134a easily causes frostbites, when it comes into contact with bare skin. When heated gases are formed and these may be harmful to lungs and the nervous

system.

The air-conditioning unit of the machine is filled with refrigerant

R134a at the factory. R134a has no damaging effect on the ozone layer of the atmosphere, however, it contributes to the greenhouse effect and must therefore never purposely be released into the open air.

IMPORTANT! R134a must never be mixed with any other kind of refrigerant, e.g. R12, as this will cause the unit to fail.


Handling hazardous substances 99

In case of contact with escaping refrigerant, the following actions must be taken:

Q

Q

The gases, which are formed when refrigerant is heated may have seriously harmful effects on lungs and the nervous system even at low concentrations and when no smell is detectable. High concentrations have a narcotic effect. An exposed person must be moved out of the danger area out into the open air. Seek medical advice if there are remaining symptoms.

In liquid form, the refrigerant may cause frostbite. Carefully heat the injured area with lukewarm water or warm clothes.

Seek medical advice, if there are remaining symptoms.

Q

Q

Seek medical advice, if liquid refrigerant has come into contact with someone's eyes.

If a leak is suspected, leave the dangerous area and contact an accredited workshop to obtain information about what action should be taken.

Batteries

WARNING!

Batteries contains sulphuric acid, which is very corrosive to skin.

Q

Q

Q

Q

Q

Q

Q

Q

Q

Do not smoke near batteries, as these give off explosive gases.

Make sure that metal objects, e.g. tools, rings and watch straps, do not come into contact with the battery pole studs.

Make sure that the battery pole stud protections always are in place.

Do not tilt a battery in any direction. Battery electrolyte may leak out.

Do not connect a discharged battery in series with a fully charged battery. Risk of explosion.

When removing a battery, disconnect the ground cable first and when installing, connect the ground cable last to reduce the risk of sparks.

Discarded batteries must be taken care of according to current national regulations.

Charging batteries, see page 123.

Starting with booster batteries, see page 124.


100 Handling hazardous substances

Dust of crystalline silicon dioxide (silica dust)

WARNING!

Avoid exposure to dust containing crystalline silicon dioxide, as it may cause serious damage to the lungs

(silicosis).

Crystalline silicon dioxide is a basic component part of sand and granite. Many activities on building sites and in mines, such as ditching, sawing and drilling, generate dust that contains crystalline silicon dioxide. 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.

L52168B

DELIVE

INS

Machines manufactur ed by

Volvo Construc tion Equipment

Machine model

Delivery instruction carried out on the

Serial no.

Construct ion Equipment

Owner

Operator (Recipient)

Customer no.

Page

1 (2)

The inspection programme “Delivery Instructions” is to be used for checking the machine with the customer/owner and for presenting the machine to the customer/owner.

Please pay atten tio n to the safety an d en viron mental ins truc tio ns in Op erator´s and Service Man uals for th e mach in es conc erned.

ARRIVAL AN D

INSPEC TION

Machines manufactur ed by


Performing, sign ing and submitti ng the delivery inst ruct ions is a pre-condit ion for a valid machine warrant y.

1 Check together with the owner/operator that the delivered machine corresponds to the order.

Construct ion Equipm ent

2 Presentation of the machine including optional equipment.

Machine Model Serial no.

Operating hours Arrival date Delivery date Page

Perfo rmed

Perfo rmed

Arriv al inspection by Delivery inspection by

3 Opera tion

The inspection programme “Arrival and Delivery Inspection” is to be used as a check on a machine upon its arrival from the factory and for an inspection before its delivery to the customer.

– Running-in instructions.

– Cab, instruments and operating controls.

Please pay atten tio n to the safety an d en viron mental ins truc tio ns in Op erator´s and Service Man uals for th e mach in es conc erned.

– Contronic functions.

MAINTENANCE OF

STORED MACHINES

Machiines manufactured by


Machine model Serial no.

Arri val inspection

– Start/stop, warming up.

Construct ion Equipm ent

Owner

1 Any deviations or transport damage must be reported to the carrier, and then immediate corrective actions must be taken.

Customer no.

– Retarder function.

1 (2)

– Steering, secondary steering.

Perfo rmed

Delivery instruction carried out on the

– Operator environment, heating, ventilation and air conditioning.

3 Check that no caps for the oil filler points, fuel tanks, radiator or expansion tank are missing, in

The inspection programme “Delivery Instructions” is to be used for checking the machine with the customer/owner and for presenting the machine to the customer/owner.

voirs and washer fluid are missing.

– Loading, digging, dumping, lifting and grading operations.

Please pay atten tio n to the safety an d en viron mental th e mach in es conc erned.

– Operation on a public road.

5 After the inspection, the anti-corrosion treatment of the machine should be renewed. If it is to be stored again for a longer period, follow the instructions in "MAINTENANCE OF STORED

Performing, sign ing and submitti ng the delivery inst ruct ions is a pre-condit ion for a valid machine warrant y.

MACHINES".

Delive ry inspe ction

– Tyre pressure.

Perfo rmed

4 Service, maint enance

Perfo rmed

Engine, cooling system and fuel system.

Review o f the Operator ’s Manual with e mphasis on the following point s.

(Depending on machine type, certain points are omitted.)

Note: Do not start engine with battery charger connected.

Perfo rmed

Power transmission / axles.

3 Opera tion

– Running-in instructions.

– Cab, instruments and operating controls.

– Contronic functions.

– Start/stop, warming up.

– Transmission, shifting gears.

– Retarder function.

– Service brakes and parking brake.

9 Start the engine and run the machine until normal operating temperature has been reached.

Check that the following systems function normally: rt AB

– Electrical system: Check that instruments, control lamps and other lights are working.

– Brake system: Test the service brakes, parking/emergency brakes and engage the retarder

(where applicable).

– Steering system: Turn the steering wheel to both full steering lock positions. When applicable, check electrical secondary steering function. On Motor Graders, lean the front wheels left and right.

– Hydraulic system: Run all hydraulic cylinders to their respective end position.

Check all equipment and functions.

– Steering, secondary steering.

10 Check that there are no fuel, water or oil leaks. If necessary, check-tighten connections, clamps and fittings.

– Operator environment, heating, ventilation and air conditioning.

11 Any malfunctions or defects must be corrected, noted and reported to the supervisor.

See page 2.

– Operation on a public road.

– Towing.

– Tyre pressure.

4 Service, maint enance

Volvo Construction Equipment Customer Suppo rt AB

SE-631 85 Eskilstuna

Sweden

Engine, cooling system and fuel system.

Electrical system including battery state of charging and starting with booster batteries (jump starting).

Note: Do not start engine with battery charger connected.

Power transmission / axles.

Brake system.

Please send com [email protected]

ments about the Inspection Programm

Volvo Construction Equipment Customer Suppo rt AB

SE-631 85 Eskilstuna

Sweden end comments about the Inpection Programm [email protected]

[email protected]

1015444


101


For the machine to function satisfactorily and at lowest possible cost, a thorough maintenance is required.

Lubrication and service chart

The section “Lubrication and Service Chart” describes the maintenance work, which the operator can carry out. If certain operations require trained workshop personnel and special equipment, this will be indicated. See “Lubrication and service chart” page 155.

Service schedule

After every completed service at an authorised workshop, the service journal shall be filled in, see page 195. The service journal is a valuable document that can be referred to, e.g., when selling the machine.

Arrival and delivery inspection

Before the machine leaves the factory, it is tested and adjusted.

The dealer must also, if the warranty is to apply, carry out "Arrival and delivery inspections" according to applicable form, which must be signed.

Delivery instructions

When handing the machine over, the dealer must give the buyer

"Delivery instructions" according to applicable form, which must be signed, if the warranty is to apply.

Service programmes

The Service Programme should be used in connection with warranty inspections and during maintenance carried out by an authorised dealer workshop.

The intervals recommended between checks, oil changes and lubrication apply provided that the machine is used under normal environmental and operating conditions.

Warranty inspection

Two Warranty Inspections should be carried out at an authorised dealer workshop. The first within 100 operating hours and the second at the latest at 1000 operating hours.

The carrying out of these warranty inspections is a condition for the warranty to apply.

During these inspections, oil and other liquids have to be changed before the end of the regular intervals.

Maintenance

Regarding intervals for other maintenance, see the Service

Programme or the Lubrication and Service Chart in this section.

102


Cleaning the machine

The machine should be cleaned regularly with conventional car care products in order to eliminate the risk of damage to the paint finish and other surfaces on the machine.

IMPORTANT! Avoid using strong cleaning agents or chemicals in order to minimise the risk of damage to the paint finish.

NOTE! Clean the areas on the machine where dust, chips and similar may collect daily in order to minimise the risk of fire.

Recommendations for cleaning the machine

Q

Place the machine in a place intended for cleaning.

Q

Q

Q

Follow the instructions supplied with the car care product.

The water temperature must not exceed 60 °C (140 °F).

If high-pressure wash is used, keep a distance of at least

20–30 cm (8–12 in) between nozzle and machine surface. Too high push and too short distance may cause damage. Protect electrical leads in an appropriate way.

Q

Q

Q

Q

Use a soft sponge.

Finish by rinsing the whole machine with only water.

Always lubricate the machine after washing.

Touch-up the paint finish when required.

Q

Q

Paint finish maintenance

Q

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.

At first clean the machine.

Apply Dinol 77B (or corresponding transparent waxy anti-rust agent) at a thickness of 70–80 µ.

A protective layer of underseal Dinitrol 447 (or corresponding) may be applied under the mudguards where mechanical wear is expected.

Touch-up painting

Machines which are used in corrosive environment are more prone to rusting than others. As a preventive measure, damaged paint finish must be touched up and anticorrosive treatment carried out every sixth month.

1 Wash the machine with tepid water. If high-pressure wash is used, the nozzle must be kept at a certain distance to the machine. The water temperature must not exceed 60 °C

(140 °F).

2 Allow the machine to dry and then lubricate it.

3 Check if any areas of the paint finish are damaged. If this is the case – rectify these.

Dipstick

A Min.

B Max.


Engine 103

Engine

Engine oil

The engine oil level can be read off on the information display unit, see page 29. If the engine oil level is low, an alarm display is shown, see page 37.

Engine oil, checking after topping up or changing

Q

Q

The level should be between the marks on the dipstick. The difference between the MIN. and MAX. marks on the dipstick is approx. 8 litres (2.1 US gal).

Try to maintain the level at maximum, but do not overfill.

Engine oil, changing

Replace engine oil every 500 hours.

1014766

WARNING!

Take care when changing oil. Hot oil can cause burns on unprotected skin.

Conditions for intervals of 500 hours 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 is used and the fuel's sulphur content.

Engine oil of a grade that only meets API CF-4 or an oil grade lower than ACEA-E2 or API-CD must not be used.

The oil must be changed at least every sixth month, regardless of the number of operated hours.


104 Engine

Draining


2 Let down the front grille.

3 Detach draining hose (A) from the front grille.

4 Remove protective cap (B) from over draining connection (C).

5 Connect the draining hose to the draining connection.

6 Drain the oil.

7 Disconnect the hose from the 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.

D

1014864

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 (12.9 US gal) including filter.

A40E/A40E FS: approx. 54 litres (14.3 US gal) including filter.

For oil quality grades, see page 167.

A Full-flow filters

B Part-flow filter

1014765


Engine 105

Engine oil filters, replacing

Replace the engine oil filters every time the oil is changed, i.e. every 500 hours.

The filters are of the disposable type, i.e. they cannot be cleaned, but must be replaced as whole units.

Removing

1 Use a suitable tool.

Installing

2 Fill the filter with oil. Oil capacity of each filter is approx.

1.25 litres (2.6 US pint).

IMPORTANT! It is important that the filters are filled with oil 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 check the sealing surface.

IMPORTANT! After replacing oil filters, the engine must run at low idling for at least one minute.



106 Fuel system

Hand pump

1014742

Fuel system

Clean fuel of the correct quality is essential for trouble-free running of the diesel engine.

Fuel system, air bleeding

WARNING!

Make sure that fuel under high pressure cannot come into contact with unprotected parts of your body when working with fuel injection equipment.

If the tank has been run dry or if air has got into the system for other reasons, the system must be bled for air.

IMPORTANT! Under no circumstances must starting attempts be made before the system has been 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 unit.

1014743

A Secondary fuel filter

B Primary fuel filter with water trap

C


Fuel system 107

Fuel filters, replacing

Replace the fuel filters every 500 hours or when replacing the engine oil filter.

If the fuel filters become clogged earlier, an alarm screen is shown, see page 37 and the filters should then be replaced.

Removing secondary fuel filter (A)

1 Use a suitable tool for removing the fuel filter.

Installing

2 Coat the gasket with diesel fuel.


4 Then tighten the filter a further ½ a turn.

Removing primary fuel filter (B)

1 Disconnect connector (A) from the cable harness.

2 Unscrew the filter by hand or use a suitable tool.

3 Detach the plastic bowl (B) from the filter.

Installing

4 Install the plastic bowl on the new filter.

5 Coat the gasket with diesel fuel.


7 Then tighten the filter a further ½ a turn.

8 Reinstall the connector to the cable harness.

9 Bleed the system according to instructions on the previous page.


Water trap

An alarm display is shown if there is water in the fuel, see page 37. Drain the water trap as follows.

Water trap, draining

1 Connect a draining hose to draining screw (C) at the bottom of the water trap.

2 Slacken the water draining screw.

3 Tighten the water draining screw, when only clean fuel is running out.


A Connector

B Plastic bowl

C Draining screw

1014763


108 Fuel system

Fuel prefilter

1048492

Fuel prefilter, changing (optional equipment)

Change the filter insert every 250 hours. More frequent changes may be needed depending on fuel consumption and fuel grade.

Change shall also take place in connection with changing primary and secondary fuel filters after an alarm for clogged filter, see page 107.

Draining

Drain the filter daily. Also drain when the water trap is drained after an alarm for water in fuel, see page 107.

1 Drain the water trap of water and any other impurities by turning the 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 counterclockwise.

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 the water bowl thoroughly.

Installing

5 Install the new filter insert and press it all the way down.

6 Fill with clean diesel fuel all the way up.

7 Change the gasket for the cover and the T-handle's O-ring if needed. Brush diesel on the gasket and the O-ring.

8 Install and fasten the filter cover with the T-handle.

A

C

B

A Fuel tank cap

B Drain plug, fuel tank

C Draining hose

A9005501


Fuel system 109

Fuel, filling

If the fuel level is low, an alarm display is shown, see page 37.

Fill with fuel to prevent air from getting in to system.

NOTE! Carefully clean fuel tank cap (A) and the area around it before removing the cap.

Q

Q

Avoid spilling when refuelling, as spilled fuel collects dirt.

During the cold season, keep the fuel tank 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 protective cap.



110 Fuel system

Fuel 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

Air Lubricating oil Exhaust gases

Turbocharger, function

A Exhaust in

B Exhaust out

C Air in

D Air out


Intercooler 111

Intercooler

The engine is provided with an air-to-air type intercooler. The intercooler lowers the temperature of the induction air by approximately 100 °C (212 °F). The induction air will then have a higher density, as a result of which more fuel can be injected and combusted. This results in higher engine output, but the colder air causes less stresses on valves and pistons.

Turbocharger

IMPORTANT! Run the engine at low idle for at least half a minute after start 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 lines are also important for the function.

If noise or vibrations are confirmed in the turbocharger, change it immediately.

Only a workshop authorised by Volvo CE may carry out work on the turbocharger.


112 Air cleaner

Air cleaner

The air cleaner prevents dust and other impurities from entering the engine. The air first passes the primary filter and then the secondary filter.

The degree of engine wear depends largely on the cleanliness of the induction air. Therefore, it is very important that the air cleaner should be checked regularly and maintained correctly. Observe great cleanliness when working with the air cleaner and filters.

IMPORTANT! Do not, under any circumstances, run the engine without a filter or with a damaged one.

Check regularly that hose and pipe connections from the air cleaner to the engine induction manifold do not leak.

Always have a spare air filter at hand and keep it well protected from dirt.

Primary filter, cleaning/replacing

Clean or replace the filter every 1000 hours. If the control lamp lights up earlier and an alarm screen is shown, see page 37, cleaning or replacement must be carried out 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 cleaner cover. Under dusty and wet conditions, the cover should however be cleaned more often.


Mechanical cleaning

1 Carefully tap the end of the primary filter against a soft and clean surface.

NOTE! Do not tap against a hard object.

Cleaning with compressed air

1 Use clean and dry compressed air with a max. pressure of

500 kPa (5 bar) (73 psi). Do not hold the nozzle closer than

3–5 cm (1–2 in).

2 Blow the filter clean from the inside along the folds.

Checking filter

1 Check the filter with the aid of a lamp.

2 If there is the smallest hole, scratch, crack or other damage, the filter must be discarded.

NOTE! To discover damage more easily, this check should be made in a darkened room.

A Primary filter

B Secondary filter


Air cleaner 113

Replacement

Press with both thumbs on the primary filter (A) at the same time as you pull it out. This is to prevent the secondary filter from coming out together with the primary filter.

Secondary filter, replacing

Replace the secondary filter every 2000 hours or every third time the primary 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

Q

The secondary filter (B) works as a protective filter in case the primary filter should be damaged.

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 impurities enter the engine. Carefully check that the new secondary filter is correctly installed.


114 Additional air cleaner

A Oil bath air cleaner A35E/A35E FS

Oil bath air cleaner A40E/A40E FS

V10519094

Additional air cleaner

For machines operating under especially dusty conditions, it is recommended that an optional air cleaner should be fitted. This will provide further safety against engine damage.

EON-filter (optional equipment)

The EON filter is installed instead of the standard primary filter.

Replace the filter when the control lamp lights.

NOTE! The filter should not be cleaned.

Oil bath air cleaner (optional equipment)

The oil bath air cleaner is installed in series with the existing standard primary filter.

A35E and A35E FS have one oil bath air cleaner.

A40E and A40E FS have two oil bath air cleaners.

The particle separating ability of the oil-bath air cleaner is between

90 and 95% which, in practice, means that the primary air cleaner fitted as standard, will act as a backup filter, with a change interval 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 be removed and cleaned.

Oil bath air cleaner, maintenance

Clean the filter inserts every 2000 hours.

Clean housing and the filter inserts with diesel fuel. Avoid using petrol (gasoline), as any remaining petrol may cause the engine to surge when it is started later.

Oil bath air cleaner, changing oil

Change oil every 250 hours.

Fill up the bowl with oil of the same viscosity as that in the engine.

The oil should reach up to the ”Normalölstand” mark, but not higher.

Capacity when changing: approx. 9.0 litres (2.4 US gal).


B

C


Additional air cleaner 115

D

E

G

H

F

Engine air precleaner, two-stage


The precleaner is located over the engine hood, on the end of the air inlet pipe. The first stage (E) separates larger impurities which then are returned immediately to the ambient air. The second stage (H) traps remaining impurities in a bowl (I) and these are removed via an outlet pipe (A) out through the silencer (B).

Clean the precleaner every 250 hours. If the main filter needs to be cleaned or changed more often than every 1000 hours due to the machine's operating conditions, it is an indication that the precleaner also needs to be cleaned more often.

Cleaning the engine air precleaner

A

A Outlet pipe

B Silencer

C Non-return valve

D Ejector port

E First stage

F Netting

G Tapered adapter

H Second stage

I

H

H Second stage

I Bowl for collecting dirt

J Connection for outlet pipe

1020077

J

WARNING!

Always use safety glasses and suitable clothing when using compressed air.

1 Disconnect the outlet pipe (A) from the second stage (H).

2 Start the engine and run at high idle.

3 Check if the suction (vacuum pressure) in the outlet pipe is acceptable by placing a piece of paper over the end of the pipe.

– If the paper stays in place, the suction is strong enough.

– If the suction is 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 the tapered adapter (G) from the second stage (H).

7 Check if there is dirt in the second stage.

8 Clean the bowl (I) and the connection for the outlet pipe (J) with compressed air if there is dirt.

9 Reconnect the outlet pipe to its connection.

10 Turn the precleaner (E, F, G) upside down.

11 Insert your hand and spin the rotor.

1020079

WARNING!

Be careful when inserting your hand, the stop plates in the precleaner may be sharp. Do not use compressed air on the rotor, this may cause personal injury.


116 Additional air cleaner

– If the rotor spins freely, turn the precleaner and blow with compressed air out through the ejector port (D).

– If the rotor does not spin, contact a workshop authorised by

Volvo CE.

12 Blow 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 a workshop authorised by Volvo CE.


Cooling system 117

11445056

1020820

Cooling system

The radiator is a side-mounted, cross-flow radiator with a hydraulically driven cooling fan. A hydraulic pump installed on the engine drives the hydraulic motor of the fan.

The fan speed is automatically adapted to the engine speed and its need of cooling.

If the engine temperature becomes too high even though the coolant level is correct, the radiator should be cleaned.

If the engine temperature still is too high, contact a workshop authorised by Volvo CE for action to be taken.

Coolant

The cooling system is filled with Volvo Coolant VCS To avoid damage to the engine, it is very important to continue using the same coolant, 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 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 is doubt as to the quality of the water, use ready-mixed coolant.

IMPORTANT! If ready-mixed coolant is used, it is very important that the correct kind is used. The engine may be damaged if different coolants are mixed.

Freeze protection down to

–25 °C (–13 °F)

–35 °C (–31 °F)

–46 °C (–51 °F)

Content of concentrated coolant

40 %

50 %

60 %


118 Cooling system

Radiator, cleaning

WARNING!

Stop the engine before cleaning the radiator.

Clean the radiator every 500 hours.


2 Open up the engine hood. The radiator is positioned on the right side in the engine compartment.

3 Blow the radiator clean with compressed air.

IMPORTANT! Take care so as not to damage the fins on the radiator core.

Coolant, checking

The coolant level can be read off on the information display unit, see 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.

WARNING!

There is a danger of scalding when removing the expansion tank cap (radiator cap), as the cooling system is pressurised when hot.

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 level must never be below the minimum mark.

C

1033923

D

A Expansion tank

B Draining hose

C Draining nipple, at rear

D Draining nipples, right side

1033924



Coolant, changing

IMPORTANT! To avoid damage to the engine, different kinds of coolant or corrosion protection must not be mixed with

each other, see page 117.

Change coolant every 6000 hours or every fourth year.

Draining

1 Remove the expansion tank cap (A).

2 Bend down hose (B) by the right side of the radiator and press in the clamp on the draining 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.


Filling

Filling with coolant is done through the expansion tank.


120 Cooling system

A

B

Filling coolant in a system which has been drained

Coolant is filled through draining nipple (C) near the bottom on the right side of the engine.

WARNING!

If the engine is started with the radiator in the swung out position, no person may be on or near the right fender.

1 The engine should be stationary and the heater control set to warm.

2 The cap for expansion tank (A) should be removed.

3 Bleeder nipple (B) should be kept open until coolant flows out.

4 Fill with coolant up to maximum level in the expansion tank.

5 Take the machine for a test drive to remove all air from 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 capacity when changing: approx. 90 litres

(23.8 US gal)

Total capacity: approx. 100 litres (26.4 US gal)

C

A Expansion tank

B Bleeder nipple

C Filler/Draining nipple

1033926

1031123



Water pump, checking belt

Q

Q

WARNING!

The engine must be stationary when checking the belt tension – rotating parts can cause injuries.

The engine must never be run when the belts are completely slack.

Check the condition of the belt every 2000 hours.

The belt is self adjusting.


122 Electrical system

A Battery disconnect switch


Check lights and control lamps daily.

Battery disconnect switch

IMPORTANT! The battery disconnect switch must not be turned off, when the engine is running.

Battery disconnect switch (A) is positioned on the left side of the cab under the entry step. After finishing work for the day, the battery disconnect switch should be turned off.

Batteries

The batteries 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 the battery electrolyte. This is particularly important in cold weather.

3 Check that the cable terminals and pole studs are clean, well tightened and coated with petroleum jelly or similar.


Electrical system 123

Checking state of charging

The state of charge of the batteries is checked with a hydrometer.

When there is risk of frost, it is particularly important that the batteries do not become discharged, as the electrolyte in a flat battery may freeze and thus destroy the battery.

Operating with faulty batteries is not allowed.

Batteries, charging

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

Q

Q

Always switch off the charging current before the charging lead clips are disconnected.

Ventilate well, particularly if the battery is being charged in a confined space.

The battery electrolyte contains corrosive sulphuric acid.

Electrolyte spilled on bare skin must be removed immediately. Wash with soap and plenty of water. Should you get splashes of electrolyte in your eyes or on any other sensitive part of your body, rinse immediately in

plenty of water and contact a doctor immediately.

1 Disconnect the cables from the battery pole studs.

2 Remove the cell caps.

3 Top up with distilled water when required.

4 Connect the charging lead clips with plus to the positive pole and minus to the negative pole.

5 Make sure that the battery charger is set to the correct voltage.

6 Switch on the charger.



Starting with booster batteries

WARNING!

Because of current surge the batteries may explode if a charged battery is connected to a completely discharged battery and this may cause injuries.

IMPORTANT! The booster batteries or another power source must have the same rated voltage as the batteries on the machine.

NOTE! Under no circumstances may a switched-on battery charger be connected to the batteries on the machine when an attempt at starting the engine is made, as this may damage the electronic system in the machine.

1 Turn off the battery disconnect switch

2 Remove the protections from the battery pole studs.

3 Connect two 12 V batteries in series.

4 Connect one of the jump leads between the (+) terminal on the battery of the machine and the (+) terminal on the booster battery.

5 Connect the other jump lead between the (–) terminal on the booster battery and a grounding point on the machine according to the adjacent figure.

6 Connect the batteries of the machine by turning on the battery disconnect switch.

7 Wait for 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

NOTE! Before carrying out any electric welding on the machine, all connectors must be disconnected from all ECUs.

Q

The current must be disconnected with the battery disconnect switch.

Q

Q

Q

The battery cables must be disconnected from the battery pole studs.

All connectors must be disconnected from all ECUs. When disconnecting and reconnection the ECUs, the leads must be without current (the battery disconnect switch turned off and the battery cables disconnected).

Contact a workshop authorised by Volvo CE for more accurate information on how to proceed.

A A B

1031123



Alternator

The alternator installation is sensitive to incorrect connection, therefore, always follow the instructions below:

Disconnecting

Q

Battery and alternator cables must not be disconnected while the engine is running. A fault may then arise in the alternator and the electronics.

Q

Disconnect and insulate the battery cables before carrying out any work on the alternator equipment.

Battery connection

Q

Q

The connecting terminals on the battery must under no circumstances be confused. The respective pole studs have a stamped-in (+) or (–) sign. If the cables are wrongly connected, the alternator rectifier will be ruined immediately.

When disconnecting batteries, first break the circuit using the battery disconnect switch.

Alternator, belt tension

Q

Q

WARNING!



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 adjusting screw (B) so that the belt can be pressed in approx. 8 mm.

3 Tighten bolts (A) on the alternator.


Self-adjusting belt tension.

1034634

A Bolts

B Adjusting screw



A High beams

B Low beams

Electrical distribution box

The machine has an electrical distribution box installed in the cab on the left cab wall. The electrical distribution box contains most of the fuses and relays of the machine, see page 180.

If a fault should occur in one of the relays, this can temporarily be overcome, by replacing the faulty relay with one that has a less important function. The relays are identical and interchangeable.

Q

Q

WARNING!

Never install a fuse with a higher rating than that given on the decal (there is a risk of damage or fire on the circuit board).

If the same fuse is triggered repeatedly, the cause must be investigated.

Headlights, adjusting

The setting of headlights is of great importance, particularly when operating on public roads during darkness. The low beams from the headlights are of the asymmetrical type.

1 Place the machine in service position, see page 89. The battery disconnect switch shall be turned on.

2 On machines 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.

Dimensions

B

H1

H2

L

Low beams High beams

1730 mm (5 ft 8.1 in) 1430 mm (4 ft 8.3 in)

1559 mm (5 ft 8.1 in) 1559 mm (5 ft 8.1 in)

1299 mm (5 ft 8.1 in) 1559 mm (5 ft 8.1 in)

5000 mm (16 ft 4.8 in) 5000 mm (16 ft 4.8 in)

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 Turn the back piece so that hole (E) aligns with screw hole (C).

4 Install screw (C).

5 Tighten screws (D).

C Screw

D Screws

E Hole



Light bulb, replacing


2 Open the engine 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.



Bulb insert, replacing

1 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.

A Engine

B Flywheel housing with power take-off

C Transmission

D Front drive axle

E Dropbox

F Propeller shafts

G Front bogie axle

H Rear bogie axle


Power transmission 129



The oil level can be read off on the information display unit, see page 30. If the oil level is incorrect (low or high), an alarm display is shown, see page 38. If the temperature in the transmission is high, the control light is on and an alarm display is shown, see page 38.

Transmission oil, checking level after topping up or changing

IMPORTANT! Always clean around the dipstick before you check the oil level. Dirt in the oil damages the transmission.

Remember:

– The transmission may not drive correctly and thus be damaged if there is too little oil.

– Too much oil makes the oil foam, which causes the transmission to overheat.

Check the oil when its temperature is approx. 60 °C (140 °F), suitably at the end of the working shift.


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 oil level should stand 40–70 mm (1.6–2.8 in) above the minimum mark on the dipstick. The corresponding reading on the display unit is 40–70%.

6 Top up when necessary, but do not overfill.

The difference on amount of oil between the MIN. and MAX. marks on the dipstick is approx. 7 litres (1.8 US gal).

Transmission

I Oil filler pipe

J Dipstick


130 Power transmission

Transmission oil, changing

Change oil every 1000 hours. A first change of oil and replacement of oil filter should be carried out at the 100 hour warranty inspection.

WARNING!


Conditions for the 1000 hour interval to apply are that:

– the two oil filters are replaced every time the oil is changed.

– the oil filters meet the Volvo CE specifications, which is the case with genuine parts from Volvo CE.

– use oil according to recommendation on page 167

– the correct oil viscosity for the ambient air temperature is selected according to diagram, see page 167.

Draining


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 lubrication oil filter, see page 131.

Filling

8 Fill with new oil through filler pipe (B).

9 Check the level.

10 Raise the guard plates.

Capacity when changing: approx. 34 litres (9.0 US gal) including filters

For oil grade see page 167.


A Draining connection

B Oil filler pipe

V1052754

Main oil filter, positioned on the right side of the transmission



Main oil filter and lubricating oil filter, replacing

Replace the filters every 1000 hours in connection with changing oil. The filters are of the disposable type, i.e. they cannot be cleaned, but must be replaced.

NOTE! Always replace both filters at the same time.

Removing

Let down the guard plates to gain access to the filters. The main oil filter is on the right side and the lubricating oil filter is on the left side of the transmission.

1 Use a suitable 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 ½ a turn.

After installing

6 Start the engine and check that the gaskets seal. If it does not, remove the filter and check the sealing surface.

NOTE! Usually it does not help to tighten harder.


V1052755

Lubricating oil filter, positioned on the left side of the transmission



Transmission, replacing breather filter

Replace the breather filter every 2000 hours.

The filter is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

1 Undo the clamp and remove filter (A).

2 Move the clamp over to the new filter and install it.

A Breather filter

Suction strainer in power take-off, cleaning

WARNING!

Hot oil can cause severe burns on unprotected skin.

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).

B Pipe

C Adapter

D E

D Suction strainer

E Spring

F Adapter

F

1034067

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.

A Level plug

B Drain plug

C Filler pipe



Dropbox, checking oil level

Check the oil level at regular intervals.


2 Unscrew level plug (A). The oil level should be up to the hole.

Dropbox, checking for leaks

Check that there are no leaks every 250 hours.


2 Carry out a visual check for leaks.

Dropbox oil, changing

Change oil every 2000 hours. A first and a second oil change shall take place at the 100 hour and 1000 hour warranty inspections.

WARNING!



2 Remove plug (B) and drain the oil.

3 Reinstall the plug after draining.

4 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)



Dropbox, replacing breather filter

WARNING!

Hot oil can cause severe burns on unprotected skin.

Replace the breather filter every 2000 hours. The filter is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

1 Undo the clamp and remove filter (A).



A Breather filter



Draining, front axle

V1051914

Drive axles, checking for leaks

Check that there are no leaks every 250 hours.


2 Carry out a visual check for leaks.

Drive axles, changing oil

Change oil every 2000 hours. The first oil change must be carried out at the 1000 hour warranty inspection.

1 Drain the oil by removing the drain plug on the respective axle housing.

2 Reinstall the plug when all oil has run out.

3 Fill with new oil in the respective axle housing through the filler plug hole.

V1052022

Draining, front bogie axle

Draining, rear bogie axle

V1052024

Level and filler plug, front axle

V1051915

V1052025

Level and filler plug, front bogie axle

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)



V1052026

Level and filler plug, rear bogie axle

Breather filter front axle and dropbox

V1052038



Drive axles, replacing breather filters

Replace the dive axle breather filters every 2000 hours. The filter is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

1 Undo the clamp and remove the filter.



Breather filter, front bogie axle

V1052039

Breather filter, rear bogie axle

1031179

A Rubber bearings

A

1035121

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 machine.



Frame joint bearing, lubricating with grease

Applies to machines from and incl. serial no.:

A35E/A35EFS – 10836

A40E/A40EFS – 12450

Frame joint bearing, checking

Check the bearing every 2000 hours.

Frame joint bearing, checking and adjusting clearance

Check and adjust the frame joint bearing clearance every

2000 hours.

The work should be carried out at a workshop authorised by

Volvo CE.

A

A Frame joint bearing (between hitch and trailer unit)

B Grease nipples

B

1041531

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 equipped with an automatic lubrication system that lubricates the frame joint according to a pre-selected lubrication cycle, see page 162.

A Sight glass

B Cover

C Draining connection

D Breather filter



Frame joint bearing, lubricating with oil

Applies to machines up to serial number:

A35E/A35EFS – 10836

A40E/A40EFS – 12450

Checking

Check the bearing every 2000 hours.

Checking and adjusting clearance

Check and adjust the frame joint bearing clearance every

2000 hours.

The work should be carried out at a workshop authorised by

Volvo CE.

Checking oil level

Check the oil level every 250 hours.


2 Read off the oil level on sight glass (A).

Changing oil

Change oil every 2000 hours. The first oil change must be carried out at the 1000 hour warranty inspection.


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 spillage.

Capacity when changing: approx. 3 litres (0.8 US gal)



Changing breather filter

Replace the breather filter every 2000 hours. Filter (D) is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

1 Undo the clamp and remove the filter.

Move the clamp over to the new filter and install it.


138 Brake system

Brake lining, min. thickness 5 mm (0.20 in)

Brake system

The brake system, apart from the parking brake, which is controlled by compressed air, is all-hydraulic and has the oil tank in common with the hydraulic system. Instructions for checking oil level, changing oil and replacing filters can, therefore, be found in the hydraulics section on page 149 (apart from replacing pressureoil filter, which can be found on the next page)

.

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.

Parking brake, checking brake linings

Check the brake lining wear every 1000 hours.

The minimum measure for the parking brake linings is 5 mm

(0.20 in).

NOTE! If the linings are worn down below 5 mm (0.20 in), the brake disc may be damaged.

Parking brake, adjusting

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 sound has stopped and the pedal feels “spongy”).

NOTE! The system may still be pressurised even though a pressure gauge shows 0, depending on where the gauge is connected.

Checking accumulators

Contact a workshop authorised by Volvo CE.

Pressure-oil filter, cover


Brake system 139

Brake system, replacing pressure-oil filter

V1051385

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.

Replace the filter every 2000 hours.

Removing

1 Use a socket and ratchet handle or suitable tool for removing the filter cover.

2 Remove the filter.

Installing

3 Install the new filter.

4 Screw on the cover.

Pressure-oil filter

V1051428


140 Brake system

V1053055

Brake indicator after the protective cap has been removed.

V1053060

Position of indicator pin below surface

Service brakes, checking brake discs

Check the brake lining wear every 2000 hours. The first check should be carried out after 500 hours.

NOTE! This applies under normal operating conditions. For harder type of operation, the brake linings must be checked more often.

To be able to check the brake disc wear, the brake pedal must be kept in the depressed position and therefore two persons are required to carry out the check.

The measuring is done on a brake indicator which is positioned in the brake back-plate on each brake drum.



3 Start the engine and run it until the control lamp for low brake pressure is extinguished.

4 Press down the brake pedal and keep the pedal in the depressed position during the entire check.

Proceed as follows with each brake:

1 Remove the protective 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)

Front axle

Front bogie axle

Rear bogie axle

X = 6.8 ± 0.1 mm (0.27 ±0.004 in)

X = 3.4 ± 0.1 mm (0.13 ±0.004 in)

X = 3.4 ± 0.1 mm (0.13 ±0.004 in)

A40E/A40E FS, (X in the table designates new linings)

Front axle

Front bogie axle

Rear bogie axle

X = 6.8 ± 0.1 mm (0.27 ±0.004 in)

X = 4.5 ± 0.1 mm (0.18 ±0.004 in)

X = 4.5 ± 0.1 mm (0.18 ±0.004 in)

If the linings are worn out, contact a workshop authorised by

Volvo CE.

4 Let up the brake pedal. Pay attention and prevent the

machine form moving.

5 Replace the protective cap on the brake indicator.

Tightening torque 30 Nm (3 kgf m) (22 lbf ft).

Brake piston, adjusting stroke clearance

The stroke clearance of the brake piston is self adjusting.

Draining connection

Draining point, hub

V1051427

Oil filter and magnetic rod

V1052760

V1052027

V1052028

Brake cooling oil tank, filling point

A

V1052032


Brake system 141

Brake cooling oil, checking level after topping up or changing

Check the oil level every 250 hours.

The level should stand 3/4 up within the measuring range on sight glass (A), which is located on the left side of the machine.

Brake cooling oil, changing

Change oil every 2000 hours.


2 Connect the draining hose to the draining connection and drain off the oil.

3 Remove the draining hose, when all the oil has run out.

4 Drain the brake cooling oil from the hubs.

5 Remove the cap from the brake cooling oil tank (positioned on the left side of the machine). Remove the oil filter from the insert and then clean the magnetic rings.

6 Install a new oil filter in the insert. Reinstall the insert in position in the oil tank and install the cover.

7 Remove the filler plug from the cover and then fill with oil through the hole until the max. level in sight glass (A) has been reached.

8 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 (positioned on the left side of the machine). Remove the oil filter from the insert and then clean the magnetic ring.

2 Install a new oil filter in the insert. Reinstall the insert in position in the oil tank and install the cover.

Brake cooling oil, replacing breather filter

Replace the brake cooling oil tank breather filter (A) every

1000 hours. The filter is of the disposable type, i.e. it cannot be cleaned, but must be replaced.

1 Remove the cover.




V1052035

Breather filter, brake cooling oil


142 Compressed-air system

Compressed-air system

Air reservoirs, draining

The machine is equipped with two compressed air tanks, a

4-litre tank (A) and a 20-litre tank (B) located on the left side behind the cab.

The air reservoirs are kept free from condensation water through an air drier.

In case of a fault in the air drier, the 20 litre reservoir can be drained through valve (E) manually.

1044826

A

A Air reservoir

B Air reservoir

B

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.

1034962

D Drier cartridge

D

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 is positioned to the left behind the cab.

1034958

E

Air reservoir

E Drain valve

F Filler valve

F

1044827

A Filler valve


Tyres 143

Tyres

A

V1052136

WARNING!

Make sure that you stand to one side of the tyre when inflating a tyre fitted on a split rim. Tyres fitted on such a rim may explode causing injury or death. Use a self attaching air chuck with a hose long enough to enable you to be out of the trajectory path when filling the tyre with air.

Tyres, checking air pressure

Check the air pressure every 500 hours.

Regarding recommended air pressure, see page 187.

Tyres, checking wear

Check the tyre wear every 500 hours.

Tyres, inflating

Filler valve (A) on the machine may preferably be used for inflating tyres or cleaning in connection with maintenance work. The filler valve is positioned to the left behind the cab.

Connecting hose:

1 Remove the cover.

2 Connect the hose.

Wheel nuts, check-tightening

After replacement of 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.


144 Cab

A Cover

B Nuts

C Prefilter

D Side guard

E Casing

F Main filter

Cab

Cab, ventilation filters

The machine is equipped with two ventilation filters in the cab, one prefilter and one main filter. The clogging up of the filters is entirely dependent on the working environment of the machine. The prefilter should be checked and cleaned when required.

IMPORTANT! The cab filters are only intended to separate particles (dust) from the air. Any dangerous gases are not trapped by the filter.

Cab, replacing prefilter


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


1 Remove side guard (D).

2 Detach casing (E).

3 Remove main filter (F).

NOTE! The main filter should not be cleaned, but must be replaced.



Cab 145

Asbestos filter (optional equipment)

WARNING!

If it is dangerous dust, e.g. toxic or contains asbestos, special measures must be taken to prevent the dust from spreading further.

The filter is especially intended for use in environments where there may be asbestos dust, but it is of course effective against all other kinds of dust when the operator needs highly filtered air in the cab.

The filter is approved according to DOP MIL standard 282 and fulfils the requirements according to the Swedish Work Environment

Authority's regulations ”Asbestos” AFS 1996:13. It also fulfils the requirements according to EN 1822:1 filter class H13.

Pay attention to the national regulations regarding work in the environment in question.

Advice for operating in environments where dust / asbestos dust is present

Q

Q

Q

Q

Q

Q

Q

Enter and leave the machine away from the asbestoscontaminated area to avoid asbestos dust being brought into the cab.

Keep clothes and shoes clean from dust as far as possible.

Tidy and vacuum-clean the cab often and use personal protective equipment, for instance respirator (dust mask) intended for asbestos contaminated areas.

The cab door must be closed. It is particularly important that the tightness (the seals) of the cab is (are) preserved/maintained.

The cab should be ventilated through its ventilation system, which also provides excess pressure in the cab.

Replace filters (main filter and prefilter) every 1000 hours or more often when required. Take care not to damage the new filters. When installing check that the edge of the filter forms a tight seal.

Handling of used filters must be done bearing the health hazard and the environment in mind. Before the filters are discarded at the place intended for asbestos waste, the filters must be placed in the tight-sealing plastic bag which is supplied with all new filters.


146 Cab

Cab air precleaner (optional equipment)

Change the system's filter every 1000 hours.

E

A

B

A Precleaner

B Worm clamp

C Clamps

D Filter casing

C

G

E Rain cap on inlet

F Outlet to evaporator housing

G Ejector ports

D

1020090

1020091

F

WARNING!

Always use safety glasses and suitable clothing when using compressed air.

Cleaning cab air precleaner

1 Loosen the worm clamp (B) that holds the filter casing (D).

2 Loosen the clamps (C) that hold the filter casing in place and move the filter casing away from the precleaner (A).

3 Remove the filter casing from the air cleaner and leave the pipe for the outlet on the filter casing in place.

4 Remove the rain cap (E) and blow away any dirt with compressed air.

5 Blow out through the two ejector ports (G) and inside the precleaner. Make sure that dirt has not collected in the precleaner.

6 Check that the fan inside 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 that the outside of the pipe, to be inserted in the air filter, is kept clean.

9 Reinstall the filter casing in reverse order. If you detect that there is some system malfunction, contact a workshop authorised by Volvo CE.

B Window washer reservoir

C Filling point

D Boot box


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.


148 Cab


Condenser, cleaning

Clean the condenser every 500 hours or as needed.



3 Open up the engine hood.

4 The condenser is positioned on the right side in the engine compartment.

5 Blow the condenser clean with compressed air.

In order to prevent leakage and to safeguard the lubrication of the seals in the compressor for the air conditioning, the air conditioning should be run for approx. five minutes once a month. It is important that the operator of the machine is made aware of this.

NOTE! At temperatures below freezing, 0 °C (+32 °F), the unit must be run indoors, if possible, as the power supply to the compressor lead is switched off by the thermostat whenever the evaporator temperature is below +1 °C °C (+34 °F).

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.

Compressor, checking belt tension

A

A Bolts

B Adjusting screw

A B

1031123

Q

Q

WARNING!



Check the condition of the belt for the first time at 250 hours

(also after replacement) and then every 2000 hours.

The compressor and the alternator have the belt in common.


1 Loosen bolts (A) on the alternator.

2 Adjust with adjusting screw (B) so that the belt can be pressed in approx. 8 mm.

3 Tighten bolts (A) on the alternator.


Self-adjusting belt tension.

1034634

1

Draining hydraulic oil

V1052762

Filling point, hydraulic oil

V1052030


Hydraulic system 149


IMPORTANT! Exercise cleanliness when filling oil and in all work on the hydraulic system

Hydraulic oil

The hydraulic oil level is read off on the sight glass located on the left side of the machine.

The oil level can also be read off on the information display unit, see page 31. If the oil level is too low, an alarm display is shown, see page 39. If the temperature in the transmission is too high or low, the control light is on and an alarm display is shown, see page 39.

Hydraulic oil, checking level after topping up or changing


NOTE! If the machine is equipped with an FS-system, the machine must be in normal position and the dump body must be empty.

2 The oil level should be checked before the engine is started.

3 The oil level should be 3/4 up within the measuring range between the lines on the sight glass (A).

NOTE! If the machine 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 with any other biologically degradable hydraulic oil.

WARNING!



2 Lower the guard plate

3 Drain the oil by removing the drain plugs (2 pcs) at the bottom of the hydraulic tank and at the rear end by the wheels (draining of sludge and condensation water is done through the same holes).

4 Fill oil through the hydraulic oil filter after removing the filler plug.

5 Reinstall the plug.

Capacity when changing A35E/A40E: approx. 245 litres

(64.7 US gal)




150 Hydraulic system

Return oil filters

V1052031

If the machine is equipped with FS-system:

1 Place the machine in the service position (level position), see page 89.

2 Make sure that the FS-system is in bottom position, see page

27. Let the engine run at idle for approx. 3 minutes so that the accumulators are drained of oil and pressure.

3 Carry out draining according to the above method.

4 Fill oil through the hydraulic oil filter after removing the filler plug.

5 Reinstall the plug.

6 Start the engine and activate the FS-system to normal position by using the switch, see page 27.

7 When the FS-system is in normal position, stop the engine and check the oil level and top up when required.

Capacity when changing A35E FS/A40E FS: approx. 275 litres

(72.6 US gal)



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 every 2000 hours. A first change of the return oil filters as well as cleaning of the magnetic rods shall take place at the 1000 hour warranty inspection.

1 Detach the covers.

2 Remove the filters which are of the disposable type.

3 Clean the magnetic rods thoroughly and install new filters.

4 Check the O-rings.

5 Reinstall the covers.

V1052032

Magnetic rod

1

Hydraulic system, breather filter

Replace breather filter (D) every 1000 hours.

1 Remove the cover.



Breather filter, hydraulic system

V1052034

Return oil filter, cooling fan

V1051429


Hydraulic system 151

Cooling fan, replacing return oil filter

IMPORTANT! Exercise cleanliness when filling oil and in all work on the hydraulic system.

Replace oil 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.



152 Dump body

A Front rubber cushions

B Rear rubber cushions

Dump body

WARNING!

Keep away from the area under the dump body when it is raised, unless it has been secured with the dump body lock and the tipping (dumping) control has been blocked with the lock-out control, see pages 48 and 94.

Check the dump body rubber cushions, which fit up against the top of the trailer unit frame, every 1000 hours. A first check should be carried out after 100 hours and also after replacing.

Rubber cushions, checking and adjusting vertically

Before checking, the respective rubber cushions and the top of the frame should be cleaned.

The dump body must be empty and lowered onto the frame and the tipping control in position 2 operating position (lowering/ floating position). When adjusting, it is important that any clearance and compression becomes the same on both sides of the trailer unit frame.

The front cushions (A) should have the same clearance between cushion and frame, 8–12 mm (0.31–0.47 in).

The rear rubber cushions (B), positioned over the bogie, should fit up against the body and be compressed to the same extent on both sides.

Adjust with shims under the rear rubber cushions (B).

Use shims according to the Parts Catalogue for 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 permissible at each tipping joint bearing.

Adjust with adjusting washers (A).

For adjusting the axial clearance of the tipping joint, use adjusting washers.

At the front side guide of the dump body, a clearance of max. 1 mm

(0.04 in) on either side is permissible. Adjust with shims.

After any adjustment, check that the end surface of the horizontal lock screws does not protrude outside the guide plate. Otherwise there is a risk of damage to the side guide or rear frame.

Dump body, rear attachment

A Adjusting washers


Dump body 153

Exhaust heated dump body


In order to prevent excavated material from freezing to the body, the machine can be equipped with a flexible tube between the tractor unit and the dump body, so that exhaust gases from the engine can be used for warming up the dump body. The flexible tube is provided with an over-load protection (A).

If the tube works loose:

1 Slacken the bolts for locking tabs (A).

2 Reposition the tube.

3 Tighten the bolts.

Maintenance 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.

A Bolts for lock plate

B Surfaces to be cleaned and lubricated

A

B

It is important that the engine has the correct back pressure in the exhaust system.

The exhaust pipe (A) must be left in place and provided with a pipe end (B), which is provided with a restriction.

A Exhaust pipe

B Pipe end with restriction

1006476


154 General inspection of machine

General inspection of machine

All earthmoving machines are to a great extent exposed to strains and wear. Therefore it is essential that they are checked and investigated regularly regarding structural damage and that all systems are functioning correctly.

It is important that regular inspections are carried out to minimise the risk of accidents and break downs. The intervals between these inspections depend on factors such as the age of the machine, type of application, additional structures, loading, the condition of the transporting road and the kind of routine service that has been carried out on the machine. Haulers, which are working under particularly severe operating conditions, require more frequent inspections, but we recommend that these inspections are carried out for the first time at 6000 hours and then every 2000 hours up to and including 12000 hours and thereafter every 1000 hours.

A workshop authorised by Volvo CE should preferably carry out the inspections.

If the machine 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 availability while at the same time the risk of accidents is reduced. The correct repair of frames and other supporting elements require knowledge of the materials, the design of the frame parts and the manufacturer's recommended repair technique. If the need of repairs arises it is recommended that you get in touch with your Volvo CE distributor, who is qualified to carry out the repairs that may be needed. We do not recommend that repairs are carried out by others than an authorised Volvo CE distributor.

The front and rear frames, the hitch and the dump body must be carefully inspected regarding crack formations and defects. This applies particularly to the welded construction elements.

The areas, which are dealt with here are particularly important, but this does not mean that other parts may be disregarded. The entire structure must be carefully examined.

Lubrication point, grease

Lubrication point, oil

Oil/liquid

Water

Fuel

Anti-freeze

Air


Lubrication and service chart 155

Lubrication and service chart

Greasing bearings

Lubrication is an important part of preventive maintenance. The service life of bushings, bearings and bearings pins can be extended considerably, if the machine is lubricated in a correct way. A lubrication chart makes lubrication work easier and reduces the risk of forgetting greasing points.

Lubrication has two main purposes:

– To supply grease to the bearing to reduce wear between the pin and the bushing.

– To replace old, dirty grease. The grease stored inside the outer seal collects dirt 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 key for “Lubrication and service chart”

These standard symbols are used in the Lubrication and service chart, see the adjacent table.

Pressure Maintenance/

Engineer

Transmission Tyres

Filter

Control lamp

Draining

Level check

Belt tension

Brake

Hydraulic system

Engine

Differential and hub reduction gear

Battery


156 Lubrication and service chart

10 hour, 50 hour, 250 hour, and 500 hour service

1046083



Measure

DAILY (every 10 hours)

Check the brake function

Check function of control lamps, operating controls, travel and working lights, and that there are no leaks.

Lubricate frame joint*

Page

136

Item

2

2

Measure

EVERY 50 HOURS

After carrying out Daily service

Page Item

Check the oil in oil bath air cleaner (optional equipment) 114

Warranty inspection should be carried out after the first 100 hours according to Service Programme

Page Item Measure

EVERY 250 HOURS

After carrying out Daily and 50 hour services

Check oil level, frame joint bearing**

Check for leaks from dropbox (visual check)

Check oil level, brake cooling oil

Check belt tension, alternator and AC compressor

(optional equipment)***

Lubricate steering joints and steering cylinder rear bearings

Lubricate tipping joint bearings

Lubricate tipping cylinder bearing

Grease propeller shafts, dropbox

137

133

141

125 and 148

3

4

6

10

7

9

19

Measure

EVERY 500 HOURS

After carrying out Daily, 50 and 250 hour services

Check brake discs, wear.

Check air pressure and wear, tyres

Check condenser

Check steering joint bearings

Check anti-freeze, coolant

Check electrolyte level, battery

Change fuel filter****

Change filter, water trap****

Change oil and oil filter, engine*****

Grease propeller shaft, dropbox – front axle

Page

140

143

148

118

122

107

107

105

Item

*) Manual greasing

**) Oil lubrication

***) Check for the first time at 250 hours and then every 2000 hours.

****) Or when changing the engine's oil filter. If the filter becomes clogged earlier, it must be replaced.

*****) For conditions for the interval of 500 hours to apply, see page 103.

15

5

16

17

11

12

13

14

18

10





Measure Page Item

Warranty inspection should be carried out after the first 1000 hours according to Service Programme

EVERY 1000 HOURS

After carrying out Daily, 50, 250 and 500 hour services

Check play in bearings and pivot pins, steering cylinder attachment.

Contact authorised workshop.

6

7

8

Check rubber cushions, dump body

Check brake linings, parking brake

Check rubber bearings on the FS-cylinders*

Replace breather filter, fuel tank

Change or clean primary filter in air cleaner

Replace prefilter, cab

Change oil and replace filters, transmission (main oil filter and lubricating oil filter)

152

138

135

110

112

144

130

2

3

4

5

Replace return oil filter, brake cooling system

Replace breather filter, brake cooling oil tank

Replace breather filter, hydraulic tank

Lubricate ball joints, exhaust flexible tube for body heating

Clean cover, air cleaner

Clean ball joints, exhaust flexible tube for body heating

Clean magnetic rod, brake cooling system**

141

141

150

153

113

153

141

3

9

11

11

11

12

9

*) For the first time at 4000 hours and then every 1000 hours.

**) Included in warranty service. Contact workshop authorised by Volvo CE.



Checks, oil changes and lubrication

Intervals: every 2000 hours (for symbol key, see page 155)



Measure

EVERY 2000 HOURS

After carrying out Daily, 50, 250, 500 and 1000 hour services

Check belt tension, water pump

Check frame joint bearing

Change oil, frame joint bearing*****

Change breather filter, frame joint bearing*****

Check steering joint bearings*

Change oil, hydraulic / brake systems**

Replace return oil filter, hydraulic / brake systems

Change brake cooling oil

Change coolant***

Replace secondary filter

Replace main filter, cab

Replace filter insert, oil bath air cleaner (optional equipment)

Replace return oil filter, cooling fan

Replace pressure-oil filter, hydraulic / brake systems.

Change oil, dropbox

Replace breather filter, dropbox

Replace breather filter, transmission

Change oil, drive axles

Replace breather filter, drive axles

Replace drier cartridge, compressed-air system

Lubricate covers, hinge, joints and locks

Clean magnetic rods, hydraulic system

Clean suction strainer, power take-off

Adjust clearance, frame joint****

Page

121

136, 137

137

137

149

150

141

119

113

144

114

151

139

133

133

132

134

135

142

150

132

Item

2

10

10

10

1

1

8

8

12

12

6

7

4

5

14

16

17

18

1

15

10

*) Check every 6000 hours. Checking should be carried out by workshop authorised by Volvo CE.

**) 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 with any other biologically degradable hydraulic oil.

***) Change coolant every 6000 hours.

****) Contact workshop authorised by Volvo CE.

*****) Oil lubrication


162 Automatic greasing

Reservoir for lubricant

1048496

Automatic greasing

The machine may be equipped with an automatic greasing system which automatically greases many points according to a preselected lubrication cycle. The automatic greasing system should be inspected regularly and should be co-ordinated with other regular maintenance and control.

Check the following regularly:

– that there is sufficient lubricant in the reservoir. Fill when required, see below.

NOTE! Too low lubricant level constitutes a great risk of air entering the system (the most common cause of operating problems).

– that the system functions. Carry out the system test on page

165.

– that the lubricant reservoir is undamaged.

– that the connections do not leak.

– that the dust guards for quick-action couplings are installed and undamaged.

– that the lubrication lines are undamaged and well secured.

– that the lubrication point is lubricated (that lubricant is forced out at the bearing).

P

l

1048497

A

A Control lamp for lubrication in progress

A

C C

B

A

B

C

B

Reservoir

Dosage block

Main line

C

B

1044703

Filler connector

1041515


Automatic greasing 163

Filling lubricant

Lubricant must be topped up before the level falls below the minimum marking on the reservoir.

There is a filling connection (grease nipple) on the pump, to which a hand pump or industrial pump can be connected for filling.

NOTE! If an industrial pump is used, the filter between the connection and pump must be cleaned regularly. A partly blocked filter can easily burst, with a consequent great risk of small particles entering the lubrication system. This may in turn lead to a breakdown in the lubrication system.

Proceed as follows:

1 Carefully clean the filler connection and the coupling on the filler hose.

2 Fill the filler hose completely full with grease before beginning to fill. This will prevent air from entering the system.

3 Remove the protective cap on the filler connection and connect the coupling to the filler connection.

4 Fill with lubricant to the maximum level on the reservoir.*) If it is hard to pump in the lubricant, either the filter behind the filler connection is blocked or there may be dirt in the filler nipple itself. Clean the filter, if required replace the nipple and try again.

5 Re-install the protective cap.

6 Keep the lubrication pump in a dust-free place, so that it will not be exposed to dirt.

*) If the reservoir is filled above the maximum level, the surplus lubricant will be drained through the ventilation hole on the left side of the reservoir. Any air under the plate in the reservoir is also drained through the ventilation hole.



Grease points

1

2

6

5 4

7

8

10

11

3

1044701

3

4

5

1

2

6

14

Steering cylinder

Upper tipping cylinder

Dump joint

Lower tipping cylinder

Steering joint

Upper tipping cylinder

1044702

13

12

7-10 Frame joint bearing (between hitch and trailer unit)

11 Steering joint

12

13

14

Steering cylinder

Lower tipping cylinder

Dump joint


Automatic greasing 165

Recommended lubricants

The system requires that the lubricant is clean and possible to pump at the prevailing temperature. Therefore use lubricant of a recommended NLGI class. A lower NLGI class grease, may reduce the lubrication effect with increased wear as a consequence.

Q

Q

Q

Do not mix different types of lubricants. When changing, all lubricant must be changed, not only in the reservoir.

There must be no additives or graphite or Teflon in the lubricant.

The use of molybdenum disulphide (MoS

2

) is only permitted if:

– the lubricant is of a very high quality and does not contain more than 5% MoS

2

.

– the lubrication system is regularly checked to provide reliable operation.

– the main lines are flushed through at least once a year.


Lowest temperature

Above -25 °C (-13 °F)

Below -25 °C (-13 °F)

Below -25 °C (-13 °F)

Below -25 °C (-13 °F)

Test button

Highest temperature

+80°C (176 °F)

0 °C (32 °F)

+80 °C (176 °F)

0 °C (32 °F)

1041514

Lubricant type, NLGI

2

0 / 1

Synthetic 2

Synthetic 0 / 1

NOTE! Special tools are required for fault tracing, adjusting and repairing the control unit. Therefore, contact qualified service personnel when required.

System test

In order to check the function of the greasing system, or to initiate an extra lubrication cycle after for example the machine has been washed, a system test can be carried out. The test button, which is used to begin a system test, is positioned at the front on the pump.

A test cycle can only be carried out when the pump is between two ordinary lubrication cycles (not during an ongoing lubrication cycle).

Single test lubrication cycle

The pump only carries out one lubrication cycle via one main line. May be used after a wash in order to obtain an extra

lubrication cycle.

1 Turn the ignition key to position 1 (running position).

2 Press in the test button for 2–6 s.

3 The lubrication cycle starts.

4 The test cycle is ended automatically.

If the test lubrication cycle has been used to obtain extra lubrication cycle after a wash, the test button should be pressed once more to lubricate the other main line.



1043496

A

Continuous test lubrication cycle

The pump carries out an unlimited number of lubrication

cycles, i.e. it continuously pumps out lubricant alternatively via the two main lines. This is used for bleeding the system of air.


2 Press the test button for more than 6 s.

3 The lubrication cycle starts.

4 End the test cycle by turning the ignition key to position 0.

The test cycle is not ended automatically.

Bleeding the system

The pump must not be activated for longer than five minutes.

1 Make sure that the lubricant reservoir has been filled up to the max. mark.

2 Remove the plugs for the main lines (A), one at a time, in the dosage block that is farthest from the pump unit.


4 Press the test button for more than six seconds, which will initiate 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 ignition key to 0-position and install the plug.

7 Follow points 2–6 in order to bleed the other main line.

8 Test the system using method “Single test lubrication cycle”, see previous page.

Cleaning with high-pressure washer

Normally water cannot penetrate into the system. However, during a high-pressure wash the risk increases and the pump unit should be protected, as water, which has entered the system, does not disappear by itself, but could instead cause operating problems.

After a high-pressure wash a ““Single test lubrication cycle” should be carried out to obtain extra lubrication.

Specifications

Recommended lubricants 167

Specifications


The viscosity indications are according to SAE J 300 MAR93.

Other mineral oils can be used if they conform to our viscosity recommendations and meet our quality requirements.

The approval of Volvo CE is required, if any other oil base quality (e.g. biologically degradable oil) is to be used.

Regarding questions about oils and lubricants please contact a workshop authorised by Volvo CE.

In case of lower ambient temperatures than in this recommendation, please contact a workshop authorised by

Volvo CE for information.

ENGINE

Oil grade

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

Recommended viscosity at varying ambient temperatures

SAE 5W/30

SAE 10W/30

SAE 15W/40

SAE 30

SAE 40

1020035

AXLES Volvo Super Gear oil

Volvo Transmission oil 97316

GO101, 75W-90

GO101

1015380

FRAME JOINT

DROPBOX

Lubricating with grease

Grease

See page 169

Lubricating with oil

Volvo Transmission Oil

SAE 80W-90

Volvo Super Gear oil


GO101, 75W-90

1012444

GO101

1015380

BRAKE COOLING,

HUB REDUCTION

GEAR

Volvo Super Wet Brake

Transaxle Oil


WB 102

WB 102

1012448

Specifications

168 Recommended lubricants

TRANSMISSION Volvo Automatic

Transmission Fluid

Volvo Transmission Oil 97341

Volvo Transmission Oil 97341

1015381

HYDRAULIC

SYSTEM

Volvo Super Hydraulic Oil

Swedish norm SS 15 54 34 alternatively international norm

Vickers 35 VQ/25 test viscosity acc. to ISO 3448 grade acc. to ISO 6743-4

V46/AV 46

V68/AV 68

ISO VG 46 HV

ISO VG 68 HV

NOTE! As an alternative, Volvo

biodegradable hydraulic oil is also available. Contact your local

Volvo service workshop for information.

COOLING SYSTEM Volvo Coolant VCS

For further information, see page 117

Engine oil

< 0.3 %

Sulphur content of the fuel

0.3–0.5 %

Oil change interval

> 0.5 % Oil grade

Volvo Ultra Diesel Engine oil

VDS-3

VDS-2 plus ACEA-E7

VDS-2 plus API CI-4

VDS-2 plus EO-N Premium plus

VDS-2

VDS plus ACEA-E3

ACEA: E7, E5, E4

API: CI-4, CH-4, CG-4

500 hours

250 hours

125 hours

250 hours

125 hours

75 hours

125 hours

75 hours

50 hours

Specifications

Recommended lubricants 169

Grease

Grease on a lithium base together with EP additives and consistency No. NLGI- 2 without molybdenum disulphide additive (MoS

2

).

Coolant

Use the same coolant as the system was filled with previously. To avoid damage to the engine, different kinds of coolant must not be mixed with each other.

When using concentrated coolant and clean water, the mixture should contain 40–60 % concentrated coolant and

60–40 % clean water. The amount of concentrated coolant must never be less than 40 % of the total mixture, see table below.

Freeze protection down to

–25 °C (–13 °F)

–35 °C (–31 °F)

–46 °C (–51 °F)

Content of concentrated coolant

40 %

50 %

60 %

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:

Description

Total number of solid particles

Total hardness

Chloride

Sulphate pH value

Silica

Iron

Manganese

Electrical conductivity

Organic content, COD-Mn

Value

< 340 ppm

< 9.5 ° dH

< 40 ppm

< 100 ppm

5.5 – 9

< 20 mg SiO

2

/litre

< 0.10 mg Fe/litre

< 0.05 mg Mn/litre

< 500 µS/cm

< 15 mg/litre

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.

Specifications

170 Recommended lubricants

Fuel system

Quality requirements: The fuel should at least meet the current legal requirements, national and international standards for marketed fuels, e.g. EN590 (with nationally adapted temperature requirements), ASTM D 975 No.

1-D and 2-D, JIS KK 2204.

Sulphur content: According to current legal requirements (the sulphur content must however not exceed

0.3 percent by weight), see also page 103.

Bio-diesel fuel

Vegetable oils and / or esters, also called “bio-diesel”, (e.g. rape-seed methyl ester RME fuel), which are offered on certain markets both as pure 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 the engine oil change interval to a half

– Shortened service life of rubber materials in the fuel system

– Less good cold handling properties of the fuel

– Limit storage time for the fuel, which may cause clogging up of the fuel system if the machine is laid up for longer periods

Warranty condition

The warranty does not cover damage caused be an intermix of more than 5% of bio-diesel fuel.

Specifications

Capacities and intervals between changes 171

Capacities and intervals between changes

Capacities

Engine incl. filter, A35E/A35E FS

Engine incl. filter, A40E/A40E FS

Cooling system

Transmission incl. filter and cooler

Dropbox

Front axle

Front the bogie axle

Rear bogie axle

Frame joint bearing (between hitch and trailer unit)

Hydraulic system A35E/A40E

Hydraulic system A35E FS/A40E FS

Brake cooling oil

Oil bath air cleaner (optional equipment)

When changing

49 litres (12.9 US gal)




8.5 litres (2.2 US gal)









Fuel tank, A35E/A35E FS

Fuel tank, A40E/A40E FS

Total

480 litres (127 US gal)


Oil and fluid changes

Engine


Coolant

Transmission

Dropbox

Drive axles

Frame joint

Brake cooling oil

Brake/Hydraulic oil

Hours

500*

250

6000**

1000***

2000

2000

2000

2000

4000****

*) For conditions which have to be met, if the interval is to apply, see page 103.

**) Change coolant every 6000 hours or every fourth year.

***) For conditions which have to be met, if the interval is to apply, see page 130.

****) For conditions which have to be met, if the interval is to apply, see page 149.

Page

103

114

117

130

133

134

137

141

149

Specifications

172 Capacities and intervals between changes

Filter replacements

Engine

Oil filters

Secondary fuel filter

Primary fuel filter

Primary filter, air cleaner*

Secondary filter, air cleaner

Breather filter, fuel tank

Hours

500

500*

500*

1000

2000

1000

Page

105

107

107

112

113

110

*) If the filter gets clogged earlier, it must be changed. EON-filter can be installed instead of the standard primary filter and should be changed when the control light comes on, see page 114.

Transmission

Main oil filter

Lubricating oil filter

Breather filter

1000

1000

2000

131

131

132

Dropbox

Breather filter 2000 133

Drive axles

Breather filter

Brake system

Pressure-oil filter

Breather filter, brake cooling oil tank

Oil filter, brake cooling oil tank

Compressed-air system

Drier cartridge

Cab

Pre filter

Primary filter


Breather filter, hydraulic oil tank

Return oil filters

Return oil filter, cooling fan

2000

2000

1000

1000

2000

1000

2000

1000

2000

2000

135

139

141

141

142

144

144

150

150

151

Specifications

Engine, specifications 173

Engine, specifications

Designation

Flywheel output at 30 r/s (1800 rpm)

SAE J1995 Gross

SAE J 1349 Net

DIN 6271

Torque at 20 r/s (1200 rpm)

SAE J1995 Gross

SAE J 1349 Net

DIN 6271

A35E/A35E FS

D12D

313 kW (426 hp)

309 kW (420 hp)

309 kW (420 hp)*

**

2100 N m (214 kgf m) (1549 lbf ft)

2056 N m (210 kgf m) (1517 lbf ft)

2056 N m (210 kgf m) (1517 lbf ft)

A40E/A40E FS

D16E

350 kW (476 hp)

346 kW (471 hp)

346 kW (471 hp)***

****

2525 N m (258 kgf m) (1862 lbf ft)

2493 N m (254 kgf m) (1839 lbf ft)

2493 N m (254 kgf m) (1839 lbf ft)

*) with the cooling fan running at basic speed. With the fan at maximum speed the output is 301 kW (409 hp) which coincides with DIN 70020.

**) with the cooling fan running at basic speed. With the fan at maximum speed the torque is 2010 N m

(205 kgf m) (1483 lbf ft) which coincides with DIN 70020.

***) with 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

Cylinder bore

Stroke

Cylinder capacity, total

6

130.17 mm (5.125 in)

150 mm (5.91 in)

12 litres (732 in

3

)

6

144 mm (5.669 in)

165 mm (6.496 in)


Compression ratio

Order of injection

Idling speed, low

Idling speed, high

18.5:1

1-5-3-6-2-4

10 ±0.8 r/s (650 ±50 rpm)

35 r/s (2100 rpm)

Valve clearance, cold engine inlet exhaust

0.20 mm (0.008 in)

1.60 mm (0.063 in)

Oil pressure, min. Warm engine, low idle,

1200 rpm

365 kPa (52.9 psi)

Oil pressure, max. Warm engine, high idle,

1800 rpm

475 kPa (68.9 psi)

18.5:1

1-5-3-6-2-4

10 ±0.8 r/s (650 ±50 rpm)

35 r/s (2100 rpm)

0.20 mm (0.008 in)

1.60 mm (0.063 in)

370 kPa (53.7 psi)

440 kPa (63.8 psi)

Air cleaner

Type

Pre filter

Dry filter together with secondary filter

Cyclone cleaner


Specifications

174 Fuel system, specifications

Fuel system, specifications

Feed pump

Type

Make

Feed pressure, at idling speed

Gear pump

Bosch

350–450 kPa (51–65 psi)

Cold-starting device

Type

Power, electrical element

Time relay (integrated), engagement time

Electrical element

2 kW

Variable

Unit injectors

Electronically controlled regarding injection amount and injection timing

Number of 6 pcs

Specifications

Cooling system, specifications 175

Cooling system, specifications

Cooling fan

Type 8-blade

Thermostat

Type

Number of

Begins to open at

Fully open at

Pressure

Piston-type thermostat

1

82 °C (180 °F)

92 °C (198 °F)

50 kPa (0.5 bar) (7.3 psi)

Specifications

176 Electrical system, specifications

Electrical system, specifications

System voltage

Batteries

Battery voltage

Battery capacity

Chassis connection

Alternator, output

Current, max.

Starter motor, output

A35E/A35E FS

24 V

A40E/A40E FS

24 V

2 pcs 12 V connected in series 2 pcs 12 V connected in series

12 V 12 V

170 Ah each

Negative terminal

1540 W

80 A

7.5 kW (10.2 hp)

225 Ah each

Negative terminal

1540 W

80 A

7.5 kW (10.2 hp)

Battery electrolyte density

Fully charged battery

The battery should be charged at

Bulbs

The light bulbs must be of the highest quality; shake-proof and with long service life.

Tractor unit

Headlamps

Parking lights

Direction indicators

Working lights (optional equipment)

Instrument lighting

Switch

Main instrument, control lamps

Main instrument, lighting

Watt

70 W

5 W

21 W

70

1.2 W

2 W

1.2 W

1.2 W

Rotating warning beacon (optional equipment) 70 W

Socket

H7

Ba 15s

Ba 15s

H3

Glass socket and integrated holder

Ba 9s



H1

Trailer unit

Tail lights

Stop lights


Reversing lamp

1.28 kg/dm

3

1.25 kg/dm

3

1 W

7 W

21 W

70 W

LED

LED

Ba 15s (The whole insert must be replaced)

H3

Specifications

Electrical system, specifications 177

Fuses


1 2 3

G

4 5 6

(V 2-E C U )

7 8

5A

22

5A

5A

23

D -E C U

T-E C U

V-E C U

(V 2-E C U )

10A

5A

24

T-E CU

15A

15A

25

15A

26

V-E CU D -E C U

15A 3A

15A

27

5A

28

15A

29

15A

R E 1

T-E C UV-E C U

D -E C U

(V 2-E C U )

R E 10

15A

R E 2

V-E C U

(V 2-E C U )

5A

R E 11

T -E C U

E -E C U

1048483

9

10A

30

R E 12

10

5A

31

R E 13

11

5A

32

12

E-ECU

15A

33

R E 14

13

5A

34

R E 15

Tachograph

C areTrack

14

15A

R E 3

15A

R E 4

10A 25A

R E 5

15A

R E 6

5A

15 16 17 18 19 20 21

5A

35

5A

36

5A

R E 7

R E 16

10A

37

15A

R E 8

15A

38

5A

15A

39

15A

R E 9

15A

40

5A

41

Tachograph

C areTrack

5A

42

10A

31A

5A

R F 3601

S TO P

10A

R E 17 R E 18

V OLV O C E 15020138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

+30

22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 5 6

34 35 36 37 38 39

7 8

40 41 42

9

10 11 12 13 14 15 16 17 18

P1 P2 P3 P4 P5

P7

P6

RFX

V1052901

1

2

3

4

Marking

Rated current

Description

5 A

5 A

5 A

15 A

Marking

Switch exhaust brake, engine brake, switch brake pedal, increased engine rpm, shift lock-out, load and dump brake, dump lever lock-out position

Position sensor throttle pedal, position sensor gear selector, position sensor retarder pedal, position monitor low range/high range, position monitor throttle pedal, position monitor retarder pedal, position monitor parking brake

12

Position monitor dump body 13

Position monitor seatbelt, position monitor seat cushion, position monitor shut-off valve hydraulic oil tank, pressure monitor return oil filter hydraulic oil, pressure monitor return oil filter cooling fan oil, socket service display unit

14

Switch parking brake 15

Rated current

15 A

5 A

5 A

5 A

Description

E-ECU, Feed 28VD C E-

ECU (including function engine stop)

Low beam, right

Low beam, left

High beam, right

Specifications


5

6

7

8

9

Marking

Rated current

Description

10

11

15 A

15 A

5 A

15 A

10 A

5 A

5 A

Marking

Interior lighting, interior lighting (left/right rear), interior lighting (right front), position monitor door

16

Rotating beacon

Direction indicators, flashing hazard lights

17

18

Fan climate control system (AC), relay climate control system (AC), monitor refrigerant pressure, monitor refrigerant temperature

Solenoid valve control compressor climate control system (AC)

Switch transverse diff. lock (front axle), longitudinal diff. lock/6×6, all diff. locks/

6×6

Position monitor longitudinal diff. lock

19

20

Preheating induction air 21

Exhaust brake, exhaust gas recirculation 22

Rated current

10 A

15 A

15 A

15 A

5 A

5 A

5 A

Description

Buzzer, central warning

Unassigned

Unassigned

Back-up (reversing) lights, back-up warning, back-up camera

Voltage converter

Back-up (reversing) camera

Pressure monitor oil filter, transmission

23

24

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)

15 A T-ECU, feed 28 VDC

33

34

25 A Electric power outlet 28

VDC

25

26

27

28

15 A

3 A

V-ECU, feed 28 VDC

D-ECU, feed 28 VDC

35

36

15 A Switch headlights

Main fuse for guide lights, running lights, high and low beams for fuses 13–15,

35, 36, and 38

15 A Headlight flasher

37

38

15 A Switch windshield wiper, relay interval wiper, motor windshield wiper, switch windshield washer, relay windshield washer, motor windshield washer, switch horn, horn

5 A Running lights left/right front, front fender and rear

Control guide lights switch

Guide light switch

5 A Running lights, instrument lighting

15 A Work lights front

5 A High beam left, D-ECU signal for activating high beam

Specifications


15 A Work lights rear 29

30

31

32

5 A Switch work lights front/rear, relay work light front/rear, work lights front/rear left/ right

15 A Switch electrically heated rear-view mirrors

Heating coil rear-view mirrors left/right lower/upper

Switch seat cushion heater, heating coil seat cushion heat, switch and control light turn-around wheels

15 A Cigarette lighter

10 A Voltage converter, switch flashing hazard lights, flasher relay, tachograph

39

40

41

42

Other fuses

FC2 FC3 FC1

10 A Stop lights

5 A Ground tachograph

10 A Delayed stop

1014832

In fuse box on battery bracket over washer reservoir

Marking Rated current

FC1 50 A

Description (fuse rail)

Main fuse

FC2

FC3

150 A

40 A

Heating coil preheating

Motor hood pump

Marking Rated current

Description(blade fuse)

FH5 5 A Load and dump brake (located under right control panel)

Specifications


Relays


1 2 3

G

4

(V 2-E C U )

5 6 7 8

5A

22

5A

5A

23

D -E C U

T-E C U

V-E C U

(V 2-E C U )

10A

5A

24

15A

25

15A

26

T-E CU V-E CU D -E C U

15A 15A 3A

15A

27

5A

28

15A

29

15A

R E 1

T-E C UV-E C U

D -E C U

(V 2-E C U )

15A

R E 2

V-E C U

(V 2-E C U )

5A

R E 10 R E 11

T -E C U

E -E C U

1048483

9

10A

30

R E 12

10

5A

31

15A

R E 3

15A

R E 4

10A

R E 13

11

5A

32

12

E-ECU

15A

33

13

5A

34

25A

R E 5

R E 14 R E 15

Tachograph

C areTrack

14

5A

35

15A

R E 6

5A

15 16 17 18 19 20 21

5A

36

5A

R E 7

R E 16

10A

37

15A

R E 8

15A

38

5A

15A

39

15A

R E 9

15A

40

5A

41

Tachograph

C areTrack

5A

42

10A

31A

5A

R F 3601

S TO P

10A

R E 17 R E 18

V OLV O C E 15020138

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

+30

22 23 24 25 26 27 28 29 30 31 32 33

1 2 3 4 5 6

34 35 36 37 38 39

7 8

40 41 42

9

10 11 12 13 14 15 16 17 18

P1 P2 P3 P4 P5

P7

P6

RFX

V1052901

6

7

Marking

1

2

3

4

5

Designation

RE3701

RE3702

RE8701

RE3503

RE3605

RE3603

RE

Description

Feed 28 VDC D-, T, V-, and

V2-ECU,

Fuses FU1, FU2, FU3, FU22,

FU23

Feed 28 VDC V- and V2-ECU,

Steering RE3703, RE3705

Fuses FU4, FU25

Fan and climate control system,

Differential locks

Electrically heated rear view mirrors, working lights, seat, fuel warming

Windscreen wipers, windscreen washer and horn

Buzzer central warning

Unassigned

11

12

13

14

15

16

17

Marking

Designation

RE3705

RE3604

RE3601

RE3602

RE3606

RE3501

RE3502

Description

Feed 28 VDC E-ECU, preheating of induction air, exhaust brake, engine stop

Direction indicators, hazard flashers and headlight flasher

Windscreen wiper

Windscreen washer

Rear vision camera, tachograph

Working lights front

Working lights rear

Specifications


8

9

Marking

Designation

RE

RE4201

Description

Unassigned

Reversing light, reversing alarm and reversing camera

Feed 28 VDC T-ECU 10

Other relays

RE3703

RT8701

RE8702 RE8703

RE5502

RE5902

RE5903

RE2501

Marking

18

RFX

Designation

RE5201

RF3601

Description

Stop lights


1014948

Under right control panel

1048503

Left side of bow

1048501

Down low in electrical distribution box on left side

Marking Description

RE2501 Preheating induction air

RT8701

RE8702

Time relay for AC-engagement at start

Climate control system (AC)

Marking

RE5902

RE5903

RE3301

RE8703

RE5502

Climate control system (AC)

Parking brake

RE3704

RE8704

Description

Load and dump brake

Load and dump brake

Starter motor (down low in electrical distribution box)

Delayed stop (down low in electrical distribution box)

Climate control system (AC) (down low in electrical distribution box)

RE5901 Load and dump brake

Specifications

182 Power transmission, specifications

Power transmission, specifications

Transmission

Type

Designation

Torque converter, type

Automatic planetary type transmission with nine forward gears and three reverse gears

PT2509

Single stage with free-wheeling stator and automatic direct drive clutch (lockup)

Dropbox

Make

Designation

Power take-off

Drive

Differential locks

Longitudinal

Transverse

Drive axles

Volvo

IL2

1 for ground-dependent hydraulic pump

4-wheel drive in permanent engagement

In dropbox

In drive axles

Make

Designation, A35E/A35E FS

Designation, A40E/A40E FS

Differential carrier assembly

Tractor unit

Volvo

ARB/H35

ARB/H40

Front bogie axle Rear bogie axle

Volvo

ARB/H35

ARB/H40

Volvo

ARB/H35

ARB/H40

Make

Gear ratio A35E/A35E FS

Gear ratio A40E/A40E FS

Differential lock

6-wheel drive (6×6)

Tractor unit

Volvo

2,833

3,091

Dog clutch


Volvo

2,833

Volvo

2,833

3,091

Dog clutch

3,091

Dog clutch

Drive via dog clutch in front bogie axle

Hub reduction gear

Type

Gear ratio

Wheel nuts

Tightening torques

Tractor unit

Planetary gear

6,0

800 N m (590 lbf ft)


Planetary gear Planetary gear

6,0 6,0

Speed ranges (max.)

Gear

Forward

1st gear

2nd gear

3rd gear

4th gear

5th gear

6th gear

7th gear

8th gear

9th gear

Reverse

1st gear

2nd gear

3rd gear

Specifications

Power transmission, specifications 183

A35E/A35E FS

6.2 km/h (3.9 mph)

9.0 km/h (5.6 mph)

11.0 km/h (6.8 mph)

16.0 km/h (9.9 mph)

23.0 km/h (14.3 mph)

29.1 km/h (18.1 mph)

38.5 km/h (23.9 mph)

50.9 km/h (31.6 mph)

57.0 km/h (35.4 mph)

6.9 km/h (4.3 mph)

10.0 km/h (6.2 mph)

18.0 km/h (11.2 mph)

A40E/A40E FS

5.8 km/h (3.6 mph)

8.4 km/h (5.2 mph)

10.4 km/h (6.5 mph)

14.9 km/h (9.3 mph)

21.6 km/h (13.4 mph)

27.3 km/h (17.0 mph)

36.0 km/h (22.4 mph)

47.6 km/h (29.6 mph)

57.0 km/h (35.4 mph)

6.5 km/h (4.1 mph)

9.4 km/h (5.8 mph)

18.0 km/h (11.2 mph)

Specifications

184 Brake system, specifications

Brake system, specifications

Service brakes

Type Dual circuit, all-hydraulic, wet brakes. One circuit for the tractor unit and one for the trailer unit.

Parking Brake

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.

Specifications

Compressed-air system, specifications 185

Compressed-air system, specifications

Air-pressure regulator

Cut-in pressure

Cut-out pressure

810–730 kPa (8.1–7.3 bar) (117–106 psi)

830–870 kPa (8.3–8.7 bar) (120–126 psi)

Compressor

Type

Compressed-air reservoirs

4 litres (0.14 ft

3

) regeneration reservoir

20 litres (0.7 ft

3

) circuit reservoir

Safety valve

Opening pressure

Single cylinder piston compressor

Number of

1

1

930 kPa (135 psi)

Specifications

186 Steering/hydraulic system, specifications

Steering/hydraulic system, specifications

Type of steering

Steering lock

Number of steering wheel revolutions

Pressure, max.

Hydro-mechanical articulated steering

2 × 45°

3.4 revolutions

25 MPa (3626 psi)

Tipping system

Make

Number of

Type

Tipping time

Lowering time

Tipping angle

Full Suspension

A35E/A35E FS

Volvo

2 pcs

Double-acting

12 seconds

10 seconds

70°

A40E/A40E FS

Volvo

2 pcs

Double-acting

12 seconds

10 seconds

72°

Number of cylinders

Cylinder bore, front axle

Cylinder bore, rear axles

Piston rod diameter, front axle

Piston rod diameter, rear axles

Stroke, front axle

Stroke, rear axles

Number of accumulators, front axle

Number of accumulators, rear axles

2

4

A35E FS

6

115 mm (4.45 in)

150 mm (5.91 in)

90 mm (3.54 in)

110 mm (4.33 in)

230 mm (9.10 in)

230 mm (9.10 in)

2

4

A40E FS

6

115 mm (4.45 in)

150 mm (5.91 in)

90 mm (3.54 in)

110 mm (4.33 in)

230 mm (9.10 in)

230 mm (9.10 in)

Specifications

Tyre sizes and recommended air pressure 187

Tyre sizes and recommended air pressure

If other tyres are used for than those stated, the tyre manufacturer should be contacted regarding information about the correct tyre pressure.

A35E/A35E FS

Tyre air pressure with a load of

32.5 tonnes

A35E/A35E FS 6X6

Tyres

Bridgestone 26.5 R25 VLT

Bridgestone 26.5 R25 VLT-S

Good Year 26.5 R25 RL-2+

Good Year 26.5 R25 TL-3A+

Good Year 26.5 R25 GP-4B

Good Year 800/65 R29 GP-4D

Michelin 26.5 R25 XADN

Michelin 26.5 R25 XADT

Michelin 775/65 R29 XAD

A40E/A40E FS

Tyre air pressure with a load of

37 tonnes

Tyres kPa (psi) 375 (54.5) kPa (psi) 375 (54.5) kPa (psi) kPa (psi)

375 (54.5)

375 (54.5) kPa (psi) kPa (psi)

375 (54.5)

330 (48.0) kPa (psi) 350 (51.0) kPa (psi) 350 (51.0) kPa (psi) 300 (44.0)

1007710

450 (65.0)

400 (58.0)

450 (65.0)

450 (65.0)

450 (65.0)

450 (65.0)

400 (58.0)

400 (58.0)

375 (54.5)

A40E/A40E FS 6X6

Bridgestone 29.5 R25 VLT

Bridgestone 29.5 R25 VLT-S

Good Year 29.5 R25 RL-2+

Good Year 29.5 R25 GP-4B

Good Year 875/65 R29 GP-4D

Michelin 29.5 R25 XADN

Michelin 29.5 R25 XADT

Michelin 875/65 R29 XAD65-1 kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi) kPa (psi)

300 (44.0)

350 (51.0)

300 (44.0)

300 (44.0)

315 (45.5)

325 (47.0)

325 (47.0)

275 (40.0)

1007710

400 (58.0)

375 (54.5)

400 (58.0)

400 (58.0)

375 (54.5)

400 (58.0)

400 (58.0)

350 (51.0)

Specifications

188 Cab, specifications

Cab, specifications

General

The cab is fitted on rubber elements, is insulated and has a flat floor with rubber mat.

Tested and approved as a protective cab according to ISO 3471-1994 ROPS and SAE J1040 - MAY94 (ROPS).

FOPS tested according to ISO 3449-1992.

Cab interior fittings and upholstery

Number of emergency exits

Fire retardant (fire resistant) measured according to ISO 3795-

1989

1 (right side window)

.

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

Height adjustment (rapid adjustment)


Adjustment for driver weight

Adjustment of backrest, (adjustable backrest inclination)

Upholstery

Lap type seat belt with reel

This machine is equipped with an operator seat, which meets the criteria of EN ISO 7096.

100 mm (4 in)

160 mm (6.3 in)

40–130 kg (88–287 lb)

12°

Fire resistant

Yes

Specifications

Cab, specifications 189

Vibration and sound information

Hand-arm vibrations

Emission of hand-arm vibration during real operating conditions at its intended use is less than 2.5 m/s

2

RMS

(root mean square) acceleration according to ISO 8041.


Emission of Whole-Body Vibration during real operating conditions at its intended use is according to the table below.

Typical operating conditions Vibration emission value a w,eqx

(m/s² RMS)

Loading

Transporting with load

0.29

0.64

Vibration emission value

0.41

0.89

a w,eqy

(m/s² RMS)

Vibration emission value a w,eqz

(m/s² RMS)

0.24

0.67

Dumping 0.49

Transporting without load 0.82

0.42

1.02

0.30

0.81

The following vibration directions are defined: x = longitudinally y = lateral z = vertical

The values for whole body vibrations stated above have been taken from ISO/CEN Technical Report.

NOTE! These hole-body vibration emission values were determined at particular operating and terrain conditions and is therefore not representative for all the various conditions in accordance with the intended 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 recommended.

To ensure that the whole-body vibration emission during machine use is kept to a minimum, see page 82.

Sound information

A35E/A35E FS

Sound pressure level (LpA) at operator position

(Measurement according to ISO 6396)

74 LpA dB(A)

112 LwA dB(A) Sound power level (LwA) around the machine

(Measurement according to 2000/14/EC with applicable appendices and measuring method according to ISO 6395)

Sound power level (LwA) around the machine

(Measurement according to 2000/14/EC with applicable appendices and measuring method according to ISO 6395)

With sound absorbing optional equipment

109 LwA dB(A)

A40E/A40E FS

74 LpA dB(A)

112 LwA dB(A)

110 LwA dB(A)

Specifications

190 Weights

Weights

A35E/A35E FS

The weights apply with 26.5 R25* tyres

Service weight A35E A35E FS

Front axle

Bogie

Total (incl. operator and full fuel tank)**

Maximum permissible load on front axle

Maximum permissible load on bogie

Load capacity (payload)

Total weight, max.

14700 kg (32408 lb)

13400 kg (29542 lb)

28100 kg (61950 lb)

17700 kg (39110 lb)

43900 kg (96783 lb)

33500 kg (73854 lb)

61600 kg (135805 lb)

14800 kg (32628 lb)

13700 kg (30203 lb)

28500 kg (62832 lb)

17800 kg (39242 lb)

44200 kg (98326 lb)

33500 kg (73854 lb)

62000 kg (136686 lb)

*) With 775/65 R29 tyres the weight is 200 kg (441 lb) more per axle.

**) If the machine is equipped with body height extension for light material, the service weight will be 2391 kg

(5271 lb) more.

A40E/A40E FS

The weights apply with 29.5 R25* tyres

Service weight A40E

Front axle

Bogie

15700 kg (34613 lb)

14500 kg (31967 lb)

Total (incl. operator and full fuel tank)** 30200 kg (66580 lb)

Maximum permissible load on front axle 19650 kg (43321 lb)

Maximum permissible load on bogie

Load capacity (payload)

Total weight, max.

49550 kg (109239 lb)

39000 kg (85980 lb)

69200 kg (152560 lb)

A40E FS

15800 kg (34833 lb)

14800 kg (32628 lb)

30600 kg (67461 lb)

19750 kg (43541 lb)

49850 kg (109900 lb)

39000 kg (85980 lb)

69600 kg (153442 lb)

*) With 875/65 R29 tyres the weight is 300 kg (661 lb) more per axle.

**) If the machine is equipped with body height extension for light material, the service weight will be 2506 kg

(5525 lb) more.

Specifications

Dimensional drawing, A35E/A40E 191

Dimensional drawing, A35E/A40E

The letters in the figures refer to the text on the next page.

1031128

Specifications

192 Dimensional drawing, A35E/A40E

The dimensions apply to an empty machine with 26.5 R25 tyres (A35E) and 29.5 R25 tyres (A40E)

Dimensions A35E

Overall length

Overall length, trailer unit

Dump body length, standard body

Overall height across exhaust pipe

A

A2

B

C

11182 mm (36 ft 8.2 in)

6242 mm (20 ft 5.7 in)

5531 mm (18 ft 1.8 in)

3716 mm (12 ft 2.3 in)

Height to roof of cab

Width across cab

C1

C2

3545 mm (11 ft 7.6 in)

1769 mm (5 ft 9.6 in)

Overall height across spill guard, lowered dump body**** 3951 mm (12 ft 11.6 in)

Overhang, towing eyes D 3101 mm (10 ft 2.1 in)

Distance, front axle – steering centre

Wheel base, drive axles

Wheel base, bogie axles

Overhang, rear

Overhang, frame

Loading height

Loading height

Height to dump body

I

E

F

G

H

J

J****

K

1278 mm (4 ft 2.3 in)

4578 mm (15 ft 0.2 in)

1820 mm (5 ft 11.7 in)

1683 mm (5 ft 6.3 in)

650 mm (2 ft 1.6 in)

2939 mm (9 ft 7.7 in)

3739 mm (12 ft 3.2 in)

2314 mm (7 ft 7.1 in)

Free tipping height

Overall height, tipped dump body


Outer turning radius

Inner turning radius

Outside width, dump body


Inside width, dump body

Lowest ground clearance, trailer unit

Ground clearance axle, trailer unit

Track width, trailer unit


Overall width, trailer unit


Lowest ground clearance, tractor unit

Ground clearance axle, tractor unit

L

M

M****

N

N1

O

O***

P

R

R1

V

V*

W

W*)**

X

X1

899 mm (2 ft 11.4 in)

7246 mm (23 ft 9.3 in)

7246 mm (23 ft 9.3 in)

8826 mm (28 ft 11.5 in)

4426 mm (14 ft 6.3 in)

3106 mm (10 ft 2.3 in)

3305 mm (10 ft 10.1 in)

2870 mm (9 ft 5.0 in)

580 mm (1 ft 10.8 in)

668 mm (2 ft 2.3 in)

2534 mm (8 ft 3.8 in)

2625 mm (8 ft 7.3 in)

3258 mm (10 ft 8.3 in)

3410 mm (11 ft 2.3 in)

521 mm (1 ft 8.5 in)

602 mm (1 ft 11.7 in)

Ground clearance, hitch

Track width, tractor unit


Overall width, tractor unit

X2

Y

Y*

Z

754 mm (2 ft 5.7 in)

2534 mm (8 ft 3.8 in)

2625 mm (8 ft 7.3 in)

3258 mm (10 ft 8.3 in)


Approach angle

Tipping angle

Max. steering lock

Z*)** a1 a2 a3

3410 mm (11 ft 2.3 in)

23.3°

70°

45°

*) A35E with 775/65R29 tyres (optional equipment)

**) A40E with 875/65R29 tyres (optional equipment)

***) With overhung tail gate

****) Applies to machines with body height extension for light material

A40E

11265 mm (36 ft 11.5 in)

6404 mm (21 ft 0.1 in)

5820 mm (19 ft 1.1 in)

3768 mm (12 ft 4.3 in)

3596 mm (11 ft 9.6 in)

1769 mm (5 ft 9.6 in)

4155 mm (13 ft 7.6 in)

3101 mm (10 ft 2.1 in)

1278 mm (4 ft 2.3 in)

4518 mm (14 ft 9.9 in)

1940 mm (6 ft 4.4 in)

1706 mm (5 ft 7.2 in)

495 mm (1 ft 7.5 in)

3152 mm (10 ft 4.1 in)

4002 mm (13 ft 1.6 in)

2455 mm (8 ft 0.7 in)

841 mm (2 ft 9.1 in)

7284 mm (23 ft 10.8 in)

7449 mm (24 ft 5.3 in)

8885 mm (29 ft 1.8 in)

4335 mm (14 ft 2.7 in)

3374 mm (11 ft 0.8 in)

3497 mm (11 ft 5.7 in)

3074 mm (10 ft 1.0 in)

628 mm (2 ft 0.7 in)

716 mm (2 ft 4.2 in)

2636 mm (8 ft 7.8 in)

----

3432 mm (11 ft 3.1 in)

3570 mm (11 ft 8.6 in)

576 mm (1 ft 10.7 in)

657 mm (2 ft 1.9 in)

806 mm (2 ft 7.7 in)

2636 mm (8 ft 7.8 in)

----

3432 mm (11 ft 3.1 in)

3470 mm (11 ft 4.6 in)

24.3°

72°

45°

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

Specifications

194 Dimensional drawing, A35E FS/A40E FS

The dimensions apply to an empty machine with 26.5 R25 tyres (A35E FS) and 29.5 R25 tyres

(A40E FS)

Dimensions A35E FS

Overall length

Overall length, trailer unit

Dump body length, standard body

A

A2

B

11182 mm (36 ft 8.2 in)

6242 mm (20 ft 5.7 in)

5531 mm (18 ft 1.8 in)

Overall height across exhaust pipe

Height to roof of cab

C

C1

3716 mm (12 ft 2.3 in)

3545 mm (11 ft 7.6 in)

Width across cab C2 1769 mm (5 ft 9.6 in)

Overall height across spill guard, lowered dump body**** 3951 mm (12 ft 11.6 in)

Overhang, towing eyes

Distance, front axle – steering centre

Wheel base, drive axles

Wheel base, bogie axles

Overhang, rear

Overhang, frame

Loading height

Loading height

I

D

E

F

G

H

J

J****

3101 mm (10 ft 2.1 in)

1278 mm (4 ft 2.3 in)

4578 mm (15 ft 0.2 in)

1820 mm (5 ft 11.7 in)

1683 mm (5 ft 6.3 in)

650 mm (2 ft 1.6 in)

2939 mm (9 ft 7.7 in)

3739 mm (12 ft 3.2 in)

Height to dump body

Free tipping height



Outer turning radius

Inner turning radius



Inside width, dump body

Lowest ground clearance, trailer unit

Ground clearance axle, trailer unit





Lowest ground clearance, tractor unit

K

L

M

M****

N

N1

O

O***

P

R

R1

V

V*

W

W*)**

X

2314 mm (7 ft 7.1 in)

899 mm (2 ft 11.4 in)

7246 mm (23 ft 9.3 in)

7246 mm (23 ft 9.3 in)

8826 mm (28 ft 11.5 in)

4426 mm (14 ft 6.3 in)

3106 mm (10 ft 2.3 in)

3305 mm (10 ft 10.1 in)

2870 mm (9 ft 5.0 in)

580 mm (1 ft 10.8 in)

610 mm (2 ft 0.0 in)

2534 mm (8 ft 3.8 in)

2625 mm (8 ft 7.3 in)

3258 mm (10 ft 8.3 in)

3410 mm (11 ft 2.3 in)

521 mm (1 ft 8.5 in)

Ground clearance axle, tractor unit

Ground clearance, hitch





Approach angle

Tipping angle

X1

X2

Y

Y*

Z

Z*)** a1 a2

602 mm (1 ft 11.7 in)

754 mm (2 ft 5.7 in)

2534 mm (8 ft 3.8 in)

2625 mm (8 ft 7.3 in)

3258 mm (10 ft 8.3 in)

3410 mm (11 ft 2.3 in)

23.3°

70°

Max. steering lock a3 45°

*) A35E with 775/65R29 tyres (optional equipment)

**) A40E with 875/65R29 tyres (optional equipment)

***) With overhung tail gate

****) Applies to machines with body height extension for light material

A40E FS

11265 mm (36 ft 11.5 in)

6404 mm (21 ft 0.1 in)

5820 mm (19 ft 1.1 in)

3768 mm (12 ft 4.3 in)

3596 mm (11 ft 9.6 in)

1769 mm (5 ft 9.6 in)

4188 mm (13 ft 8.9 in)

3101 mm (10 ft 2.1 in)

1278 mm (4 ft 2.3 in)

4518 mm (14 ft 9.9 in)

1940 mm (6 ft 4.4 in)

1706 mm (5 ft 7.2 in)

495 mm (1 ft 7.5 in)

3152 mm (10 ft 4.1 in)

4002 mm (13 ft 1.6 in)

2455 mm (8 ft 0.7 in)

841 mm (2 ft 9.1 in)

7284 mm (23 ft 10.8 in)

7449 mm (24 ft 5.3 in)

8885 mm (29 ft 1.8 in)

4335 mm (14 ft 2.7 in)

3374 mm (11 ft 0.8 in)

3497 mm (11 ft 5.7 in)

3074 mm (10 ft 1.0 in)

628 mm (2 ft 0.7 in)

658 mm (2 ft 1.9 in)

2636 mm (8 ft 7.8 in)

----

3432 mm (11 ft 3.1 in)

3570 mm (11 ft 8.6 in)

576 mm (1 ft 10.7 in)

657 mm (2 ft 1.9 in)

806 mm (2 ft 7.7 in)

2636 mm (8 ft 7.8 in)

----

3432 mm (11 ft 3.1 in)

3470 mm (11 ft 4.6 in)

24.3°

72°

45°

Service history

Service 100 hours

Date Hours

Specifications

Service history 195

Type of service

Warranty Inspection

Signature and stamp


Date Hours

Type of service

Service and maintenance

Signature and stamp


Date Hours


Date Hours

Type of service

Warranty Inspection


Signature and stamp

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp

Specifications

196 Service history


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Specifications

Service history 197

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp

Specifications

198 Service history


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Date Hours

Type of service


Signature and stamp


Accidents .......................................................................58

Additional air cleaner ...................................................114

Additional structures ........................................................7

Adjusting washers, checking and adjusting dump body sideways ..................................................................... 152

After recovering / towing ................................................73

Air cleaner ............................................................112, 173

Air conditioning (optional equipment)..................... 53, 148

Air reservoirs, draining .................................................142

Air-pressure regulator .................................................. 185

Alarm screens ................................................................37

Alternator ..................................................................... 125

Alternator, belt tension .................................................125

Anti-theft device (optional equipment) ...........................41

Arrival and delivery inspection .....................................101

Asbestos filter (optional equipment).............................145

ATC (Automatic Traction Control)

(optional equipment) ................................................49, 66

Automatic greasing ......................................................162

Batteries .......................................................................122

Batteries, charging ....................................................... 123

Batteries, checking electrolyte level .............................122

Battery disconnect switch ............................................ 122

Battery electrolyte density ............................................ 176

Before service, read .......................................................90

Body height extension (optional equipment) ..................87

Boot box .......................................................................147

Brake cooling oil, changing .......................................... 141

Brake cooling oil, checking level after topping up or changing ...................................................................... 141

Brake cooling oil, replacing breather filter ....................141

Brake cooling oil, replacing oil filter.............................. 141

Brake piston, adjusting stroke clearance .....................140

Brake system ...............................................................138

Brake system, pressure release...................................138

Brake system, replacing pressure-oil filter ................... 139

Brake system, specifications........................................184

Brakes ..............................................................................6

Braking ...........................................................................68

Bulb insert, replacing ...................................................128

Bulbs ............................................................................ 176

Cab air precleaner (optional equipment)...................... 146

Cab ..........................................................................7, 144

Cab, cleaning prefilter .................................................. 144

Cab, replacing main filter ............................................. 144

Cab, replacing prefilter .................................................144

Cab, specifications ....................................................... 188

Cab, ventilation filters...................................................144

Capacities and intervals between changes..................171

CE marking, EMC directive ..............................................9

Centre instrument panel.................................................20

Checking accumulators................................................ 138

Checking state of charging .......................................... 123

Cleaning the machine .................................................. 102

Climate control system, adjusting ..................................53

Cold-starting device ..................................................... 174

Communication equipment, installation .........................10

Component information..................................................29

Compressed-air reservoirs...........................................185

Compressed-air system ............................................... 142

Compressed-air system, filling .....................................142

Compressed-air system, replacing drier cartridge .......142

Compressed-air system, specifications........................ 185

Compressor .................................................................185

Compressor, checking belt tension .............................. 148

Condenser, cleaning ....................................................148

Controls..........................................................................43

Coolant................................................................. 117, 169

Coolant, changing ........................................................ 119

Coolant, checking after topping up or changing........... 118


199

Coolant, checking ........................................................ 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 drawing, A35E/A40E............................... 191

Display unit .................................................................... 28

Downhill operation ........................................................ 85

Drive axles ................................................................... 182

Drive axles, changing oil.............................................. 134

Drive axles, checking for leaks .................................... 134

Drive axles, replacing breather filters .......................... 135

Dropbox oil, changing .................................................. 133

Dropbox ....................................................................... 182

Dropbox, checking for leaks ........................................ 133

Dropbox, checking oil level .......................................... 133

Dropbox, replacing breather filter ............................... 133

Dump body lock ............................................................. 94

Dump body .................................................................. 152

Dump body, emergency lowering .................................. 76

Dumping load................................................................. 88

Electrical distribution box ............................................. 126

Electrical system...................................................... 5, 122

Electrical system, specifications .................................. 176

Emergency exit .............................................................. 51

Emergency hammer ...................................................... 51

Engine air precleaner, two-stage

(optional equipment) .................................................... 115

Engine hood................................................................... 93

Engine oil filters, replacing........................................... 105

Engine oil ............................................................. 103, 168

Engine oil, changing .................................................... 103

Engine oil, checking after topping up or changing ....... 103

Engine...................................................................... 5, 103

Engine, specifications .................................................. 173

Environmental requirements............................................ 5

EON-filter (optional equipment) ................................... 114

Error code screens ........................................................ 40

Exhaust heated dump body (optional equipment) ....... 153

Feed pump................................................................... 174

Filling compressed-air system ....................................... 73

Filter replacements ...................................................... 172

Fire protection................................................................ 95

Foreword.......................................................................... 1

Frame joint bearing, lubricating with grease ................ 136

Frame joint bearing, lubricating with oil ....................... 137

Fuel filters, replacing.................................................... 107

Fuel prefilter, changing (optional equipment) .............. 108

Fuel system ................................................................. 106

Fuel system ................................................................. 170

Fuel system, air bleeding............................................. 106

Fuel system, specifications.......................................... 174

Fuel tank, draining sludge............................................ 109

Fuel tank, replacing breather filter ............................... 110

Fuel, filling.................................................................... 109

Full Suspension ........................................................... 186

Full Suspension, emergency lowering ........................... 77

Full Suspension checking rubber bearings.................. 135

Fuses ........................................................................... 177

Gear shifting .................................................................. 63

Gear-shift inhibitor ......................................................... 63

General inspection of machine .................................... 154

Grease ......................................................................... 169

Greasing bearings ....................................................... 155

Guard plates, lowering................................................... 92

Handling hazardous substances.................................... 97

Headlights, adjusting ................................................... 126

Heating and ventilation system...................................... 52

Hydraulic oil ................................................................. 149


200

Hydraulic oil, changing .................................................149

Hydraulic oil, checking level after topping up or changing ...................................................................... 149

Hydraulic system.......................................................... 149

Hydraulic system, breather filter...................................150

Hydraulic system, return oil filter and magnetic rods ... 150

Identification numbers ......................................................2

Information and warning plates ......................................12

Instructor seat ................................................................50

Instrument panels ..........................................................17

Intended use ....................................................................5

Intercooler ....................................................................111

Keyboard for display unit ...............................................29

Left instrument panel .....................................................18

Lifting machine ...............................................................79

Light bulb, replacing ..................................................... 127

Loading ..........................................................................87

Lubrication and service chart ....................................... 101

Lubrication and service chart ....................................... 155

Machine operator safety ................................................58

Main oil filter and lubricating oil filter, replacing............131

Manual release of parking brake....................................74

Measures before operating ............................................61

Modifications ....................................................................7

Off-road operation ..........................................................86

Oil and fluid changes ...................................................171

Oil bath air cleaner (optional equipment) .....................114

Oil bath air cleaner, changing oil.................................. 114

Oil bath air cleaner, checking....................................... 114

Oil bath air cleaner, maintenance ................................114

Operating information ....................................................32

Operating instructions ....................................................55

Operating on inclines .....................................................85

Operating techniques .....................................................81

Operating with differential locks .....................................65

Operator comfort ............................................................50

Operator duties ..............................................................57

Operator seat .................................................................50

Other controls ................................................................43

Overspeed protection.....................................................64

Paint finish maintenance ..............................................102

Parking brake .........................................................68, 184

Parking brake, adjusting ..............................................138

Parking brake, checking brake linings ......................... 138

Parking ...........................................................................70

Plates and decals...........................................................11

Power socket .................................................................49

Power transmission..................................................6, 129

Power transmission, specifications .............................. 182

Preparations before service ...........................................92

Presentation .....................................................................5

Primary filter, cleaning/replacing .................................. 112

Product plates ................................................................11

Protection against electromagnetic interference ............10

Radiator, cleaning ........................................................ 118

Rear vision camera (optional equipment) ......................54

Rear vision system, colour (optional equipment) ...........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

Service brakes, checking brake discs.......................... 140

Service history ............................................................. 195

Service position ............................................................. 89

Service programmes.................................................... 101

Service schedule ......................................................... 101

Setting / setting to zero / acknowledgement .................. 33

Specifications............................................................... 167

Speed ranges (max.) ................................................... 183

Starting engine............................................................... 62

Starting with booster batteries ..................................... 124

Steering joint lock .......................................................... 94

Steering system ............................................................... 6

Steering ......................................................................... 67

Steering/hydraulic system, specifications .................... 186

Stopping machine .......................................................... 69

Storage space................................................................ 51

Symbol key for “Lubrication and service chart”............ 155

Table of contents ............................................................. 3

The EU EMC Directive..................................................... 9

The USA Federal Clean Air Act ..................................... 14

Tipping control ............................................................... 75

Tipping system............................................................. 186

Tipping ........................................................................... 75

Toolbox ........................................................................ 147

Touch-up painting ........................................................ 102

Towing ........................................................................... 72

Transmission oil........................................................... 129

Transmission oil, changing .......................................... 130

Transmission oil, checking level after topping up or changing ...................................................................... 129

Transmission ............................................................... 182

Transmission, replacing breather filter......................... 132

Transport operation ....................................................... 84

Transporting the machine .............................................. 78

Transporting with load ................................................... 87

Travelling and operating (working) on a public road...... 60

Turbocharger ............................................................... 111

Tyre sizes and recommended air pressure ................. 187

Tyres............................................................................ 143

Tyres, checking air pressure........................................ 143

Tyres, checking wear................................................... 143

Tyres, inflating ............................................................ 143

Unit injectors ................................................................ 174

Uphill operation.............................................................. 85

Ventilation system.......................................................... 52

Vibration and sound information .................................. 189

Visibility.......................................................................... 55

Warranty inspection ..................................................... 101

Water pump, checking belt .......................................... 121

Water trap .................................................................... 107

Water trap, draining ..................................................... 107

Weights........................................................................ 190

Welding........................................................................ 124

What to do if the machine gets stuck ............................ 71

Wheel nuts, check-tightening....................................... 143

Whole body vibrations ................................................... 82

Windscreen washer reservoir ...................................... 147

Working within dangerous areas ................................... 59

Ref.No. VOE21C1003521

Printed in Sweden

Volvo, Eskilstuna

English

CST

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