Volvo A35E User manual

OPERATOR'S MANUAL
Ref.No. VOE21C1003521 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
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.
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.
Get to know the capacity and limits of your
machine!
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.
Ref.No. VOE21C1003521
The original language is Swedish
Printed in Sweden, 2009.03
Copyright © 2009, Volvo Construction Equipment Customer Support. All rights reserved.

Foreword
2 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.
Please send comments about the Operator's Manual to [email protected]om
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

Table of contents
3
Table of contents
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

Table of contents
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
Central lubrication............................................................... 162
Specifications........................................................167
Recommended lubricants................................................... 167
Capacities and intervals between changes ........................ 171
Engine, specifications......................................................... 173
Fuel system, specifications................................................. 174
Cooling system, specifications ........................................... 175
Electrical system, specifications ......................................... 176
Power transmission, specifications..................................... 182
Brake system, specifications .............................................. 184
Compressed-air system, specifications .............................. 185
Steering/hydraulic system, specifications........................... 186
Tyre 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
5
Presentation
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 m3(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 m3(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 low-
emission 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.
1031100

Presentation
6
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, oil-
cooled, disc brakes with external cooling.
Exhaust retarder / engine retarder
Depending on the setting of certain switches exhaust brake and
engine braking are available to decrease wear of the brakes.
Parking brake
The parking brake is of 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.

Presentation
8
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.

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.
L64437A

Presentation
10 Communication equipment, installation
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:
QThe position of the aerial must be selected so that it is well
adapted to the environment.
QThe 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.
QThe 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.
QRemember 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.
A Radio aerial
B Telephone aerial / Two-way radio

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.

Presentation
12 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.
1 Attaching point for lashing. (+ decal for FS-machine) 2 Battery disconnect switch
3 Avoid directing water jet against air intakes. 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).
5 WARNING! Do not operate downhill with the gear
selector in neutral. Only change gear with the
accelerator released.
6 Air conditioning filled with R134a. Opening pressure,
safety valve (optional equipment).
7 WARNING! Do not use the overhung tail gate (optional
equipment), if 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
9 WARNING! Risk of crushing – articulated frame steering
10 WARNING! Do not remain within the working area of a
reversing machine.
1034999
11026729
1014833
Volvo Construction Equipment
A1601500
LUFTKOND. FYLLD MED 2.3 -0,1 KG R134a
ÖPPNINGSTRYCK SÄKERHETSVENTIL 38±3 BAR
AIR COND. CHARGED WITH 2.3 -0,1 KG R134a
HIGH PRESSURE RELIEF VALVE SETTING 38±3 BAR
0
0
1044759
1044760

Presentation
Plates and decals 13
11 WARNING! Rotating fan. 12 WARNING! Do not lean in under raised dump body,
unless it is blocked.
13 Brake system under pressure 14 Tyre pressure
15 Hydraulic oil 16 Fuel
17 Engine hood 18 Service decal
19 WARNING! Only use Volvo coolant VCS – read the
Operator's Manual.
20 Brake cooling oil
21 Before transporting an FS-machine on another vehicle,
lower the machine to bottom position.
22 Retarder decal (on page 85 the decal is shown in larger
format and for each machine model).
,22
1044761
1044762
4948092
A9012200
1020820
11445056
1035003
3
5
8
12
18
25
30
50
57
3
2
5
7
11
16
18
31
34
A35E
1044669

Presentation
14 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-
certified non-road engine to a non certified configuration.
The Federal regulations implementing the Clean Air Act for non-
road 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.

Presentation
16 The USA Federal Clean Air Act
Preventive Maintenance Program
To retain the dependability, noise level and exhaust emission
control performance originally built into your conventional non-
road 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 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.
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):
QVisually check unions and hose connections.
Check the condition of fuel hoses for:
QAgeing
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:
QVisually check for leaks in the intake hoses and exhaust pipe of
the turbocharger.

Instrument panels
17
Instrument panels
Keep the manual in the cab so that it always is at hand.
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!
1Left instrument panel 3Right instrument panel
2Centre instrument panel
13
2
1008392

Instrument panels
18 Left instrument panel
Left instrument panel
1 Rheostat, lights in switches
Regulates steplessly the light intensity in all switches.
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
1 Rheostat, lights in switches 4 Front working lights (optional equipment)
2 Rheostat, instrument lighting 5 Rear working lights (optional equipment)
3 Travel lights 6 Keypad for display unit
A9000301
1
2
3456
A9002500
A9002500
A9001400