Volvo EC35 User manual

OPERATOR'S MANUAL
Ref.No. VOE21B1002144 English
Printed in Sweden CST

California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.

Safety when servicing
Operating instructions
Other controls
Table of contents
OPERATOR'S MANUAL
Presentation
Instrument panels
Operating techniques
Service and maintenance
Specifications
Alphabetical index
Ref.No. VOE21B1002144
The original language is German
Printed in Sweden 2007.06
Copyright © 2007, Volvo Construction Equipment Customer Support. All rights reserved.
EC35/EC45
Foreword
This Operating Manual is intended as a guide to the correct
use and maintenance of the machine. You should therefore
thoroughly read this manual driving the machine, or before
performing any maintenance tasks.
Keep the manual in the cab so that it is always at hand. It
should be immediately replaced if it has been lost.
These operating instructions describe the applications the
machine is mainly intended for. It has been written in such a
way, that it is valid for all markets. Sections without any rele-
vance for your machine should therefore be disregarded and
skipped.
NOTE! The information contained in these operator's in-
structions applies for machine types EC35 (from serial
number: 283 18963) and EC45 (from serial number: 284
17799), if not specified differently.
Many hours of design work and development activities were
spent to produce a machine which meets the highest de-
mands with respect to safety and power. Accidents occurring
in spite of this are in most cases caused by human error. A
safety conscious person and a well maintained machine
make up a safe, efficient and profitable team. You should
therefore read and strictly observe the safety regulati-
ons.
We continually strive to improve our products and enhance
their efficiency by changing their design. We retain the right
to implement such changes without any commitment of intro-
ducing these improvements for machines in the field. We also
reserve the right to change data and equipment, as well as in-
structions for service and maintenance without prior notice.
Safety regulations
The operator is obliged to know the applicable national and
local safety regulations. The safety regulations in this manual
only apply if there are no applicable national or local regulati-
ons in effect.
Become acquainted with the working capacity
and the limits of your machine!
WARNING!
The symbol above appears at various points in the
manual together with a warning text and has the fol-
lowing meaning:
Warning, be alert! Your personal safety is involved! It
is the duty of the operator to make sure that all warn-
ing decals are legible and correctly in place on the
machine. Accidents may otherwise occur.

Foreword
2Identification numbers
Identification numbers
Enter the identification number of machine and machine parts. This number must be specified when contacting
the manufacturer to order spare parts. Positions and explanation of the PIN plates, see page 9.
Please send comments about the Operator's Manual to [email protected]
Manufacturer: Volvo Compact Equipment SAS
Rue Pierre Pingon
BP 119
F - 01303 Belley Cedex
PIN (Product Identifica-
tion Number) of machine:
Engine:

Table of contents 3
Table of contents
Foreword....................................................................1
Identification numbers ............................................................ 2
Presentation..............................................................5
CE marking, EMC directives................................................... 7
Communication equipment, installation.................................. 8
Product plates......................................................................... 9
Decals and stickers .............................................................. 10
General view......................................................................... 15
The USA Federal Clean Air Act............................................ 16
Instrument panels...................................................19
Left hand instrument panel ................................................... 20
Front instrument panel.......................................................... 21
Right hand instrument panel................................................. 22
Rear instrument panel .......................................................... 27
Other controls.........................................................29
Controls ................................................................................ 29
Cabin .................................................................................... 33
Operator's seat ..................................................................... 35
Operating instructions ...........................................37
General instructions.............................................................. 37
Safety regulations for operation............................................ 38
Measures before operation................................................... 40
Starting the engine ............................................................... 41
Stopping the engine.............................................................. 42
Loading and unloading the machine..................................... 44
Operating techniques.............................................47
Whole-body vibrations .......................................................... 48
Operation of the machine ..................................................... 50
Operating in uneven terrain or on slopes ............................. 51
Backfilling or grading ............................................................ 52
Stopping and parking the machine ....................................... 53
Lowering the attachment ...................................................... 54
Hose breakage protection .................................................... 55
Attachments.......................................................................... 56
Attaching and removing attachments ................................... 57
Hydraulic tools ...................................................................... 60
Hammer (option)................................................................... 61
Hydraulic equipment for clamshell (option) .......................... 67
Lifting .................................................................................... 69
Signalling pattern.................................................................. 70
Safety when servicing............................................73
Service position .................................................................... 73
Read before servicing........................................................... 74

Table of contents
4
Service and maintenance.......................................81
Service points ....................................................................... 83
Engine .................................................................................. 86
Fuel system .......................................................................... 88
Cooling system ..................................................................... 90
Air filter ................................................................................. 93
Electrical system................................................................... 94
Track reduction gear............................................................. 97
Tracks................................................................................... 98
Hydraulic system .................................................................. 99
Greasing the bearings ........................................................ 103
Lubrication and service chart.............................................. 104
Specifications........................................................107
Table of fuels and lubricants............................................... 107
Coolant ............................................................................... 109
Capacities, change intervals............................................... 110
Engine ................................................................................ 111
Electrical system................................................................. 112
Power Transmission ........................................................... 116
Slewing system................................................................... 117
Cabin .................................................................................. 118
Hydraulic system ................................................................ 119
Weights............................................................................... 121
Dimensions EC35............................................................... 122
Dimensions EC45............................................................... 124
Nominal lifting loads EC35 ................................................. 126
Nominal lifting loads EC45 ................................................. 128
Attachments........................................................................ 130
Service history .................................................................... 132

Presentation 5
Presentation
Intended use
The machine has been designed and built in accordance with the
latest technical standard and its safety has been tested according
to the generally accepted technical rules and regulations.
The machine must only be operated in technically perfect condi-
tion and by trained operating personnel, in strict compliance with
applicable safety regulations and accident prevention instructions.
This applies also for the compliance with the notes on safety con-
cerning maintenance, care and repair in this operating instruction
manual.
For use in special applications, such as explosive environments or
in areas characterised by asbestos containing dust one must com-
ply with particular safety regulations and the machine must be
equipped for such work.
For further information please contact the manufacturer or your
dealer.
Environmental requirements
Bear the environment in mind when operating and during service
and maintenance of the machine. Always follow local and national
environmental legislation concerning all handling of the machine.
Engine
EC35/EC45
The engine is a 4-cylinder VOLVO D2.2 type diesel engine with
water cooling.
1012096

Presentation
6
Travel system
The travel motion is accomplished by the main chassis via two rub-
ber tracks (steel tracks optionally available). The tracks are each
driven by a two speed travel motor.
Hydraulic system
Closed circuit hydraulic load sensing system, allowing full inde-
pendence of the individual movements.
Slewing system
The slewing ring is driven by a hydraulic motor, the oil supply of
which is overpressure protected by high pressure relief valves. In
case of a leak or hose rupture the slewing facility is hydraulically
braked.
Equipment
A standard or quick-release equipment carrier (option) accommo-
dates quick fitting of bucket (or other attachments).
Anti-theft device (option)
The installed anti-theft device seriously hampers stealing the
machine.
Volvo CE supplies the anti-theft device as optional equipment. If
your machine is not yet fitted with such a device you should check
a possible retrofit by your dealer.

Presentation
CE marking, EMC directives 7
CE marking, EMC directives
CE-Sign
(Declaration of Conformity)
(Applies only for machines to be sold within the European
Community)
"The machine was awarded with a CE-Sign".
This means that the machine fulfils the applicable "General Health
and Safety Requirements" of the so-called EC machine directive.
An EC Declaration of Conformity accompanies the machine as evi-
dence for the fulfilment of the above mentioned requirements. If
any conversions are made which have an adverse effect on the sa-
fety of the machine, the person introducing this modification is fully
responsible for the resulting effects.
If the machine is used for purposes other than the ones mentioned
in these operating instructions, the safety of the machine must be
assured in any case. The person applying such measures takes
full responsibility. In certain cases it may be necessary to obtain a
new CE-Sign and to issue a new Declaration of Conformity.
Volvo is only reliable for machines which are operated with
the attachments, equipment and spare parts specified by us.
Attachments (optional equipment) manufactured by us are adap-
ted integral parts of the machine. The CE-Sign therefore also co-
vers our attachments. We do not assume liability for attachments
made by other manufacturers.
Materials having an effect on noise, such as noise insulating, noise
reducing or noise absorbing materials, must not be altered or re-
moved. It is also prohibited to cut holes into cabin or engine
compartment, since this would have a negative effect on the noise
level.
EMC Regulations of the EC
Under certain conditions the electronic equipment may have an in-
terfering effect on other electronic equipment, or other electronic
equipment may interfere with the electronic equipment on the ma-
chine, which may affect safety. The EMC regulations of the EC
concerning the "Electromagnetic Conformity" contain a general
description of the requirements, which may be appropriate for the
safety of a machine, the limits of which are specified in internation-
al standards. Machines or apparatuses which meet these de-
mands are awarded with the CE-Sign. Our machines have been
especially tested for electromagnetic interference. Both the CE-
sign and the declaration of conformity refer to the EMC regula-
tions. If another piece of electronic equipment is to be fitted to the
machine it must have the CE-Sign and the machine must have
been checked for the effect of electromagnetic interference
L64437A

Presentation
8 Communication equipment, installation
Communication equipment,
installation
IMPORTANT! Any installation of optional communication
equipment must be carried out by trained professionals and
in compliance with the instructions supplied by Volvo CE
with the machine.
Protection against electromagnetic interfe-
rence
This machine has been tested in accordance with EC directive 89/
336/EEC concerning 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 such equipment can cause interference with the
electronic systems of the machine.
Mobile phones
For a reliable function the mobile phone must be permanently con-
nected to the electrical system of the machine. Apart from that a
fixed aerial must be mounted to the outside of the machine, as
specified by the manufacturer. If a portable mobile phone is used,
you should bear in mind that it may constantly transmit information
to its base station, even when not used. For this reason, it should
not be placed next to electronic equipment in the machine, such as
directly on a control panel etc.
Guidelines
The guidelines specified below must be followed during
installation:
QThe position of the aerial should be chosen in such a way, that
it is well adapted to the environment.
QThe down lead from the aerial should be of 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 good galvanic contact with the same.
QThe mating surface between the aerial mounting bracket and
the bodywork must be free of dirt and oxides. After installation
protect the mating surfaces against corrosion, as a measure to
maintain good galvanic contact.
Remember to keep interfering cables away from cables
susceptible for interference. Interfering cables are the power supp-
ly cable and the aerial cable to the communication equipment. Ca-
bles susceptible for interference are cables to and from electronic
units on the machine. Install cable harnesses as close to grounded
plate surfaces as possible, since these have a screening effect.

Presentation
Product plates 9
Product plates
The following illustrations and descriptions show the product pla-
tes on the excavator.
When ordering spare parts or for short enquiries by phone and in
correspondence you should always specify model designations
and product identification number.
1 Product plate
The product plate contains name and address of manufacturer,
model/type designation, product identification number, weight of
machine, engine power, year of manufacture, as well as CE-sign
(only in EC countries).
2 Engine identification plate
The engine identification plate is located on the valve cover.
3 Colour code
The colour code is specified on a sticker stuck to the cabin roof.
Volvo Compact Equipment sas
Volvo Compact Equipment sas
BP 119 - BELLEY Cedex - FRANCE
2N°
1
Yellow Volvo E2340086
E2340085Grey Volvo
Volvo Construction
Equipment
3
1012097

Presentation
10 Decals and stickers
Decals and stickers
Warning and information decals
The driver must be acquainted with and observe all warning and
information decals, which are attached to the machine.
Decals and stickers, which are missing or have been damaged,
must be immediately replaced. Apart from that the decals must be
kept in a legible, i. e. clean condition.
The spare parts number (ordering number) is printed on the
respective decal or can be found in the spare parts catalogue.
1 Warning decal! Operation and maintenance.
The warning decal is located under the driver's seat. The instruc-
tions and warnings in the operator's manual must be read carefully
before using the machine for the first time. The technical documen-
tation can be found under the driver's seat.
2 Warning decal! Open engine hood only with
engine stopped.
This warning decal is located on the engine hood. Due to the risk
of being injured by rotating parts it is dangerous to open the engine
hood while the engine is running.
1011332
1
3
5
2
13/14/15/16/17
9
4
8
12
18
10
19/20
11
6
7
21
22
11803665
1011261
11803662 WARNING
1011262

Presentation
Decals and stickers 11
3 Warning decal! Safety distance from the area of
action.
This warning decal is located on the rear covering and emphasizes
that a sufficient safety distance to the area of action of the machine
must be maintained to avoid injury.
4 Warning decal! Safety distance to the zone of
motion.
This decal is attached to the digger arm and emphasizes that a
sufficient safety distance to the zone of motion of the digger arm
must be maintained, in order to rule out any danger of injury.
5 Warning decal! Track tension.
This warning decal is attached to the main chassis.
It indicates that the tension of the tracks must be checked every
day.
6 Warning decal! Boom.
This warning decal is located under the operating console. Opera-
te the boom only from the driver's seat! (North America only).
7 Warning decal! No ether.
This warning decal is located in the engine compartment.
Do not use ether! Danger of injury! The engine is equipped with
electric preheating. (North America only).
11803661
WARNING
1011263
11803667
WARNING
1011264
11803669
WARNING
1011265
WARNING
OPERATE BACKHOE
FROM OPERATOR'S SEAT
ONLY
11803685
1011387
WARNING
ELECTRICAL PREHEATER BUILT IN
PERSONAL INJURY COULD RESULT
11803690
NO ETHER
1011386

Presentation
12 Decals and stickers
8 Information decal - Fuel.
This information decal is located inside the engine compartment
on the fuel tank filler neck. Fuel quality, see table of fuels and lubri-
cants on page 107.
9 Information decal - Hydraulic oil.
This information decal is located on the front of the right hand hood
and points to the location of the hydraulic oil level gauge. For qua-
lity of hydraulic oil please refer to the table of fuels and lubricants
on page 107.
IMPORTANT! If the hydraulic system is filled with biodegra-
dable hydraulic oil from the factory (see sticker on filler
neck), only the oil quality specified on the sticker must be
used to fill up or when changing the oil.
10 Information decal - Lubrication and mainte-
nance plan.
The lubrication and maintenance plan with information on lubrica-
tion and maintenance intervals is located under the engine hood;
see page 104.
11 Information decal - Sound capacity level.
This information decal is located on the front side of the frame and
contains information about the sound capacity level (LwA) around
the machine.
12 Information decal – Slewing ring lubrication.
This information decal is located on the front of the frame and in-
dicates the lubrication points in this area.
11803664
1011266
11803663
1011267
D
D
1*
5*
2*
2*
7*
4*
3*
5*
5*
9*
9*
8*
1011315
E130039A
11802898
1011260

Presentation
Decals and stickers 13
13 Information decal - Nominal lifting loads.
This information decal contains information about the nominal
transport loads of the machine and is stuck to the ceiling of the
operator's cab or the protection roof.
14 Information decal – Locking console.
This information decal is stuck to the ceiling of the operator's cab
and explains the starting procedure.
15 Information decal - Operator’s stand control
elements.
This information decal contains information about the control ele-
ments on the machine and is stuck to the ceiling of the operator's
cab.
16 Information decal – Loading, Unloading/Lifting
the machine.
This information decal is stuck to the ceiling of the operator's cab
and indicates the loading/lifting points on the machine.
Kg
L
E5750972B
1012271
>1.5 2 2.5 3 3.5 3,9 4 4.2
Z2 975 710* 540 430
____________________________________________________________________________________
Z1 1470 905 655 515 420 360
____________________________________________________________________________________
Z3 1490 925 665 520
____________________________________________________________________________________
____________________________________________________________________________________
Z2 885* 710 470* 430 350
____________________________________________________________________________________
Z1 1015* 900 650 505 410 345 325
____________________________________________________________________________________
Z3 1465 910 655 510 415
Z2 915 656 505 400
____________________________________________________________________________________
Z1 1380 850 615 480 390 335
____________________________________________________________________________________
Z3 1395 865 620 485
____________________________________________________________________________________
____________________________________________________________________________________
Z2 885* 665 470* 400 330
____________________________________________________________________________________
Z1 1015* 845 610 470 385 320 300
____________________________________________________________________________________
Z3 1375 850 610 475 390
X(m)
L:
1.2 m
L:
1.5 m
L:
1.2 m
L:
1.5 m
A
B
OK
STOP
12 3
=1+2+3 E5750985A
1012267
E5750952
N N
1012276
A
B
+
1012136

Presentation
14 Decals and stickers
17 Information decal – Tie down.
This information decal contains information about the tie-down
points for transporting the machine and is stuck to the ceiling of the
operator's cab.
18 Information decal – Emergency exit.
In events of emergency leave the cab through the emergency exit.
19 Information decal - TOPS and ROPS.
This information decal is located on the cab above the rear winds-
creen. TOPS (Tip-Over-Protection-Structure) and ROPS (Roll-
Over-Protection-Structure) provide roll over protection in case the
machine should turn over.
IMPORTANT! Therefore, hold firmly onto the machine if the
machine should tip or roll over. Do not jump off!
20 Information decal - FOPS.
This information decal is located on the cab above the rear winds-
creen. FOPS (Falling-Object-Protection-Structure) provides pro-
tection against falling down objects.
21 Information decal - Battery disconnecting
switch.
This information decal is located on the ride hand side cover. The
battery disconnecting switch is used to interrupt the electric power
supply.
22 Information decal - Seat height adjustment.
This information decal is located on the driver's seat and informs
about the height adjustment feature.
1012203
11803657
1011257
4560 KG (10055 LBS)
ROPS ISO 3471and SAE J1040
TOPS ISO 12117
283-284
1011329
283-284
1011328
1011270
1011271

Presentation
General view 15
General view
Position of the various machine compo-
nents
1 Bucket
2 Bucket cylinder
3 Dipper arm
4 Dipper cylinder
5Boom
6 Boom cylinder
7 Dozer blade cylinder
8 Dozer blade
9 Boom offset cylinder
10 Main chassis
11 Travel system
12 Tracks
13 Upper structure
14 Engine hood
15 Hydraulic system cover
16 Working headlights
2
3
1
4
5
6
7
8
9
10
11
12
13
14
15
16
1012221

Presentation
16 The USA Federal Clean Air Act
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 EPA-certi-
fied non-road engine to a non-certified configuration.
The Federal regulations implementing the Clean Air Act for non-
road engines, 40 C.F.R.Section 89.1003(a)(3)(i), reads as follows:
The following act and the causing thereof are prohibited:
For a person to remove or render inoperative a device or ele-
ment of design installed on or in a non-road engine vehicle or
equipment in compliance with regulations under this part pri-
or to its sale and delivery to the ultimate purchaser or for a
person knowingly to remove or render inoperative such a de-
vice or element of design after the sale and delivery to the ul-
timate purchaser.
The law provides a penalty of up to $2,500 for each violation.
An example of a prohibited modification is the recalibration of the
fuel system so that the engine will exceed the certified horsepower
or torque.
You should not make a change to an EPA-certified non-road en-
gine 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
event that you do not receive the warranty service to which you be-
lieve you are entitled under the Emission Control System Warran-
ty, you should contact your nearest Volvo Construction Equipment
Regional office for assistance.

Presentation
The USA Federal Clean Air Act 17
Normal Non-Road Engine Use
The Maintenance Instructions are based on the assumption that
this conventional machine will be used as designated in the Oper-
ator’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 deal-
er 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, includ-
ing 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 subse-
quent purchaser of the non-road engine.
Service Performed By Your Local Dealer
Your local dealer is best qualified to give you good, dependable
service since he has trained service technicians and is equipped
with genuine original manufacturer´s parts and special tools, as
well as the latest technical publications. Discuss your servicing
and maintenance 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 techni-
cian to work on your machine. This will aid your local dealer in ef-
forts to decrease service time on your machine.
Preventative Maintenance Program
To retain the dependability, noise level and exhaust emission con-
trol performance originally built into your conventional non-road
engine, it is essential that the non-road engine receive periodic
service, inspections, adjustments and maintenance.

Presentation
18 The USA Federal Clean Air Act
Fuel System
Fuel Recommendations
The fuel used must be clean, completely distilled, stable and non-
corrosive. 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.
In cold weather conditions, below 32 °F (0 °C), the use of lighter
distillate or higher cetane level fuel are recommended. (Final boil-
ing point max. 660 °F (349 °C) and a cetane min 45).
To avoid excessive deposit formation and to minimize the emis-
sions of sulfur dioxide into the ambient air, the sulfur content of the
fuel should be the lowest available. The diesel fuels recommended
for use in Volvo engines should meet ASTM designation: D 975
No. ID (C-B) or No. 2D (T-T); with a cetane level above 42 and sul-
fur content not exceeding 0.5 percent by weight.
Check for fuel leaks (while the engine is running at fast idle):
QVisually check unions and hose connections.
Check the conditions of the fuel hoses for:
QAging
QCracks
QBlisters
QScuffing
Check the condition of the fuel tank:
QDrain water condensation.
QCheck for cracks.
QCheck for leaks.
QCheck the mounting.
Check the turbocharger:
Visually check for leaks in the intake hoses and exhaust pipe of the
turbocharger.