Volvo EC35 Operator's Manual
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Volvo EC35 Operator's Manual

Volvo EC35 Operator's Manual

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

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Summary of Contents for Volvo EC35

  • Page 1 OPERATOR'S MANUAL Ref.No. VOE21B1002144 English Printed in Sweden...
  • Page 2 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.

  • Page 3: Foreword

    Accidents may otherwise occur. Become acquainted with the working capacity Alphabetical index and the limits of your machine! Ref.No. VOE21B1002144 The original language is German Printed in Sweden 2007.06 Copyright © 2007, Volvo Construction Equipment Customer Support. All rights reserved.

  • Page 4: Identification Numbers

    Positions and explanation of the PIN plates, see page 9. Manufacturer: Volvo Compact Equipment SAS Rue Pierre Pingon BP 119 F - 01303 Belley Cedex PIN (Product Identifica- tion Number) of machine: Engine: Please send comments about the Operator's Manual to om@volvo.com...

  • Page 5: Table Of Contents

    Table of contents 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 ...........
  • Page 6 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...

  • Page 7: Presentation

    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.
  • Page 8 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.

  • Page 9: Ce Marking, Emc Directives

    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.

  • Page 10: 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.

  • Page 11: Product Plates

    Equipment Yellow Volvo E2340086 Grey Volvo E2340085 N° Volvo Compact Equipment sas Volvo Compact Equipment sas BP 119 - BELLEY Cedex - FRANCE 1012097 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).

  • Page 12: Decals And Stickers

    Presentation 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.
  • Page 13 Presentation Decals and stickers 3 Warning decal! Safety distance from the area of WARNING 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. 11803661 1011263 4 Warning decal! Safety distance to the zone of...
  • Page 14 Presentation 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. 11803664 1011266 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.
  • Page 15 Presentation Decals and stickers 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. X(m) > 710* ____________________________________________________________________________________ 1470...
  • Page 16 Presentation 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. 1012203 18 Information decal – Emergency exit. In events of emergency leave the cab through the emergency exit.

  • Page 17: General View

    Presentation General view General view Position of the various machine compo- nents 1012221 Bucket Bucket cylinder Dipper arm Dipper cylinder Boom Boom cylinder Dozer blade cylinder Dozer blade Boom offset cylinder Main chassis Travel system Tracks Upper structure Engine hood Hydraulic system cover Working headlights...

  • Page 18: The Usa Federal Clean Air Act

    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-...
  • Page 19 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.
  • Page 20 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.

  • Page 21: Instrument Panels

    Instrument panels Instrument panels WARNING! Before taking the machine into operation you should become familiar with the location and function of all gauges and control elements. You should therefore thoroughly read these operating instructions. Your personal safety is concerned! Keep the manual in the cab so that it is always at hand when needed.

  • Page 22: Left Hand Instrument Panel

    Instrument panels Left hand instrument panel Left hand instrument panel The left hand instrument panel contains switches for the ope- ration of attachments and optional equipment. 1 Quick release system unlocking switch (option). 2 Switch for rotating beacon (option). 3 Quick release system unlocking switch (option). 4 Reserve (option).

  • Page 23: Front Instrument Panel

    Instrument panels Front instrument panel Front instrument panel 1 Offset/slewing control light. Control light (reserve, option). 2 Switch for working head lights. 3 Switch for fast travel speed. 1012224 1 (A) Offset/slewing control light 1 (B) Control light (reserve, option). 2 Switch for working lights on boom (option) –...

  • Page 24: Right Hand Instrument Panel

    Instrument panels Right hand instrument panel Right hand instrument panel The right hand instrument panel contains control elements to start, stop and secure the machine. 1 "PUMA" instrument panel 2 Anti-theft device (option) 3 Ignition switch 1012225 1 "PUMA" instrument panel The "PUMA"...
  • Page 25 Instrument panels Right hand instrument panel Control lights and buttons with an audible warning signal (Deactivation or confirmation of function) 1 Preheating control light Ignition key in "Running/Preheating" position, the control light lights up and goes out as soon as the engine has reached the specified operating temperature.
  • Page 26 Instrument panels Right hand instrument panel Control lights with 3 audible warning signals (standard warning) 6 Hydraulic oil temperature control light – Control light flashes (without audible warning signal) if the oil temperature is too low. – The control light comes on if the temperature is too high. 7 Hydraulic oil filter control light –...
  • Page 27 Instrument panels Right hand instrument panel PUMA self-test NOTE! After switching off the electric power supply, manually by means of the battery disconnecting switch (optional equip- ment) or by the internal function of the "PUMA"-control, the control will run a self-test after switching the electric power supply back on with the battery disconnecting switch or by turning the ignition key to position "2".
  • Page 28 Code (cur- Factory code rent) + – If both codes are unknown, or have been inadvertently edited, you must inform the customer service department of Volvo about the serial number of the machine, so that the anti-theft Setting the new Code device can be deactivated.

  • Page 29: Rear Instrument Panel

    Instrument panels Rear instrument panel Rear instrument panel The rear instrument panel contains switches for cabin venti- lation, cleaning of windscreens and optional functions. 1 Cab ventilation switch. 2 Switch for cleaning of windscreen. 3 Reserve. 4 Radio with cassette player (option). 1012228 1 Cab ventilation switch –...
  • Page 30 Instrument panels Rear instrument panel 4 Radio with cassette player (option) 1011246 1 Memory button 2 Memory button 3 Memory button 4 Search/ fast search 5 Volume - volume type 6 Mute - mute on/off 7 Volume control 8 On / Off 9 Display 10 Cassette player / station selection 11 Automatic saving...

  • Page 31: Other Controls

    Other controls Controls Other controls Controls 1012118 Throttle lever Left hand control lever for excavator attachment Selector switch "Slewing or Offset" Safety lock for working and travel hydraulics Pedal for optional equipment Control levers for travel motion Warning horn switch Right hand control lever for excavator attachment Dozer blade control lever...
  • Page 32 Other controls Controls 1 Throttle lever – Pull the lever back to raise the engine speed. – Push the lever fully forward before shutting down the engine. 1012121 2 Left hand control lever for excavator attach- (LH) ment (ISO control pattern) –...
  • Page 33 Other controls Controls 5 Pedal for optional equipment – Pedal for optional equipment, such as hammer or clamshell (option). – Actuation of the pedal executes the function of the optional equipment. 1011226 1012190 6 Control levers for travel motion – Push both levers forward: Forward travel. 1012122 –...
  • Page 34 Other controls Controls 9 Dozer blade control lever The control lever controls the height of the dozer blade. – Lever forward: Dozer blade down. – Lever backward: Dozer blade up. A Button to activate fast travel speed gear. – Hold button depressed: Fast speed is activated. 1012127 –...

  • Page 35: Cabin

    Other controls Cabin Cabin Access to cab – The cab door is fitted with an external door handle with a lock (1) and an internal door handle (4). – The door can be locked in open position by application of ma- nual force (a fixed locking bolt (3) on the cab engages in the round bolt receptacle (2) in the door).
  • Page 36 Other controls Cabin Interior equipment 1 Loudspeaker 2 Cab light 3 Adjustment of the heating at the right under the operator's seat. 4 Storage compartment for operator's manuals 5 Ventilation or warm air nozzle. 6 Fuses in cab. 1011251 7 Washing water tank filler neck. 8 Possible location for fastening a fire extinguisher.

  • Page 37: Operator's Seat

    Other controls Operator's seat Operator's seat A correctly adjusted operator’s seat is an essential contribution to operator comfort and safety! Operator’s seat settings WARNING! Do not adjust the operator’s seat while the machine is mov- ing. Horizontal adjustment – Pull lever (1) slightly up: –...
  • Page 38 Other controls Operator's seat...

  • Page 39: Operating Instructions

    Operating instructions General instructions Operating instructions General instructions The following text is a compilation of rules which should be follo- wed and recommendations which are intended to be of assistance when operating the machine. However, the rules do not relieve the operator from obeying local laws and other national safety regulations.

  • Page 40: Safety Regulations For Operation

    Operating instructions Safety regulations for operation Safety regulations for operation Duties of the driver Before starting to drive read the operating instructions to become familiar with the machine. The operator should know and take into consideration the re- quirements and risks at the workplace and discuss these with the site management.
  • Page 41 Operating instructions Safety regulations for operation Safety of the operator The machine must be in functional condition. Faults that may lead to accidents must be rectified. Wear suitable protective clothing for safe operation of the machine. A mobile phone should not be used if it could interfere with the functions of the electronic system.

  • Page 42: Measures Before Operation

    Operating instructions Measures before operation Measures before operation 1 Before taking the machine into operation you should become familiar with the location and function of all gauges and control elements. You should therefore thoroughly read these opera- ting instructions. Your personal safety is concerned! 2 Before starting the engine walk around the machine and check for any leaks and damaged or loose parts which could cause damage.

  • Page 43: Starting The Engine

    (position 2). The "Preheating " control light (1) lights up. Pre- 1011259 heat depending on engine temperature. EC35: 15 seconds. EC45: 15 seconds. The preheating control light goes out after preheating. Howe- ver, if the ignition key remains in "Preheating" position (position 2), the preheating function remains active, even though the control light is off.

  • Page 44: Stopping The Engine

    Operating instructions Stopping the engine Stopping the engine 1 If possible park the excavator on a solid, level base and lower the working attachment to the ground. 2 Reduce the engine speed: Set the throttle lever to "idle speed position". NOTE! Do not shut the engine down all of a sudden from full load, but let it idle for a short while for temperature equaliza- tion.
  • Page 45 Operating instructions Stopping the engine Long-term parking IMPORTANT! If the machine is not going to be used every day, all cylinders should be greased as protection against corrosion. 1 Wash the machine down and touch up any damaged paint fi- nish to avoid rusting.

  • Page 46: Loading And Unloading The Machine

    Operating instructions Loading and unloading the machine Loading and unloading the mach- WARNING! When transporting the machine pay attention to applicable regulations regarding weight, width, height, length and securing the load. Make sure that the ramp is of ample width, stability, thickness and length. Remove sludge, grease, oil etc.
  • Page 47 – Remove any attachments. – The the distance (C) between axis (A) and axis (B) at the lifting point on the boom must be observed when lifting. Type Distance (C) mm EC35 EC45 1011327 Towing WARNING! Use a steel rope of suitable strength to tow the machine.
  • Page 48 Operating instructions Loading and unloading the machine...

  • Page 49: Operating Techniques

    Operating techniques Operating techniques The following pages contain pieces of advice and instructions on how to operate the machine as well as examples of how to use the most common attachments. The employment of the correct opera- ting technique is of utmost importance for safe and efficient opera- tion of the machine.

  • Page 50: Whole-Body Vibrations

    Operating techniques Whole-body vibrations Whole-body vibrations Whole-body vibration emissions on construction machinery are af- fected 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.
  • Page 51 Operating techniques Whole-body vibrations Back pain associated with whole-body vibrations may be caused by other risk factors. The following guidelines can be effective to minimize risks of back pains: – Adjust the seat and controls to achieve good posture. – Adjust the mirrors to minimize twisted posture. –...

  • Page 52: Operation Of The Machine

    Operating techniques Operation of the machine Operation of the machine – Adjust the engine speed with the throttle lever (1). – Raise excavator equipment and dozer blade with control levers (8) and (9). – Forward travel: Press both travel levers (6) forward. –...

  • Page 53: Operating In Uneven Terrain Or On Slopes

    Type Permissible incli- Manageable gradi- nations during ents (engine lubri- work* cation) EC35 = 31,5% (17,5°) = 58% (30°) EC45 = 34,5% (19°) = 58% (30°) * ( = 50% of tipping limit) 1012194...

  • Page 54: Backfilling Or Grading

    – Lever to the right: Lateral offset to the right. – Lever to the left: Lateral offset to the left. This work can be accomplishes under confined spatial conditions. The minimum radius R1 of the excavator equipment is as follows. EC35 EC45 Offset in degree (°) to left 80°...

  • Page 55: Stopping And Parking The Machine

    Operating techniques Stopping and parking the machine Stopping and parking the mach- – Use control levers (2) and (8) to park the excavator on a solid, level base and lower the working attachment to the ground. – Reduce the engine speed: Set the throttle lever to "idle speed position".

  • Page 56: Lowering The Attachment

    Operating techniques Lowering the attachment Lowering the attachment In technical incidents the attachment can be lowered to the ground. Lowering the attachment using accumula- tor pressure In case of standstill or engine defect. If the electric power circuit is available and the accumulator is pressurized, it is possible to lower the attachment with the control elements.

  • Page 57: Hose Breakage Protection

    If the pressure in the accumulator is no longer high enough for lowering the attachment, you should secure the working area and consult an authorized Volvo CE workshop. Ensure that no persons are near the working area of the machine.

  • Page 58: Attachments

    CE-Sign. This cer- tification therefore also covers the attachments, which are desig- ned and marketed by Volvo CE, as they are an integral part of the machine and have been adapted to the machine.

  • Page 59: Attaching And Removing Attachments

    Operating techniques Attaching and removing attachments Attaching and removing attach- ments WARNING! Never use any attachment, unless you have checked that it is securely fastened and that the attachment including hydraulic hoses, hose connections and other components is free of damage. Your personal safety is concerned. Installing a bucket with manual fastening 1 Position the excavating equipment to the bucket to be installed.
  • Page 60 Operating techniques Attaching and removing attachments Bucket installation with manual quick release sys- Fastening the bucket 1 Position the excavating equipment to the bucket to be installed (Fig. A). 2 Align the tapered pins on the equipment carrier to the fitting groove on the bucket (Fig.
  • Page 61 Operating techniques Attaching and removing attachments Bucket installation with quick release system The quick release system consists of the special attachment car- rier mounted to the dipper arm. The moveable plate (1) on the car- rier locks the system in place. Attachment carrier and bucket have tapered pins (2) and fitting grooves (3) for fastening.

  • Page 62: Hydraulic Tools

    Operating techniques Hydraulic tools Hydraulic tools Volvo CE offers a wide range of hydraulic tools. All tools and op- tions are described in the Attachment Catalogue. Please consult your authorized Volvo CE dealer for more detailed information. WARNING! Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all directions, in order to relieve any trapped pressure.

  • Page 63: Hammer (Option)

    Operating techniques Hammer (option) Hammer (option) The hammer is mainly used in road construction, in demolishing work and work with rock material. Different hammer chisels are av- ailable to suit a vast variety of applications. WARNING! Safety regulations, operating instructions and maintenance instructions issued by the hammer manufacturer must be strictly observed! 1016543...
  • Page 64 Operating techniques Hammer (option) Detaching the hammer 1 Place the machine on firm and level ground. 2 Lower the boom and lay the hammer flat on the ground. WARNING! Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all directions, in order to relieve any trapped pressure.
  • Page 65 Operating techniques Hammer (option) Attachment and removal of hammer with quick fastening Attaching the hammer 1 Place the machine on firm and level ground. Position the mach- ine as required for the hammer laying flat on the ground. 2 Slowly lower the boom, until the tapered journals of the attach- ment carrier are in line with the fitting grooved on the hammer.
  • Page 66 Operating techniques Hammer (option) Removing the hammer (manual quick fastening) The hammer is removed outside the machine with the help of a metal bar (1) (part of the on-board equipment), which is used to operate the releasing mechanism on the interlocking plate (4). 1 Place the machine on firm and level ground.
  • Page 67 Operating techniques Hammer (option) Removing the hammer (quick fastening) The hammer is operated from the operator's stand via the hydrau- lically actuated unlocking device. 1 Place the machine on firm and level ground. 2 Lower the boom and lay the hammer flat on the ground. WARNING! Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all...
  • Page 68 Operating techniques Hammer (option) Working with the hammer Precautions WARNING! When working with the hammer no other persons should remain in the danger zone! Wear suitable protective clothes to protect yourself against flying stone chips. Danger of severe injury! IMPORTANT! If the hammer is connected to an attachment carrier the attachment carrier must be regularly inspected for damage! The windscreen must be kept closed and locked during ham-...

  • Page 69: Hydraulic Equipment For Clamshell (Option)

    Operating techniques Hydraulic equipment for clamshell (option) Hydraulic equipment for clams- hell (option) The hydraulic equipment for the clamshell enables the connection and use of a clamshell. WARNING! Safety regulations, operating instructions and maintenance instructions issued by the clamshell manufacturer must be strictly observed! Installing the clamshell 1 Place the machine on firm and level ground.
  • Page 70 Operating techniques Hydraulic equipment for clamshell (option) Removing the clamshell 1 Place the machine on firm and level ground. 2 Lower the boom and lay the clamshell flat on the ground. WARNING! Before removing or connecting hydraulic hoses the engine must be shut down and the control levers shifted to all directions, in order to relieve any trapped pressure.

  • Page 71: Lifting

    IMPORTANT! Various countries have their own regulations concerning the use of the machine for lifting work, e.g. to lift freely suspended loads. For more detailed information you should contact your authorized Volvo CE dealer. IMPORTANT! Observe the nominal transport loads of the machine on page 126!

  • Page 72: Signalling Pattern

    Operating techniques Signalling pattern Signalling pattern Manual signals to the driver of a mobile excavator acc. to SAE J1307. Hand signals are mainly used by the signalling person as a means to direct the lifting, handling and positioning of loads fastened to the attachment. Hand signals may also be used during earth moving work and/or when moving the machine with limited visibility.
  • Page 73 Operating techniques Signalling pattern 1005894 1005897 1005895 EXTEND ARM RETRACT TELESCOPIC BOOM EXTEND TELESCOPIC BOOM Both hands form fists, thumbs Both hands form fists, thumbs Both hands form fists, thumbs point outward. point inward. point outward. 1005898 1005899 1005900 CLOSE BUCKET OPEN BUCKET SWING THE COMPLETE One hand closed without movement.
  • Page 74 Operating techniques Signalling pattern 1005909 1005908 1005907 SLOW MOVEMENT STOP EMERGENCY STOP Hold one hand still in front of the hand One arm stretched out to the side, the Both arm stretched out to the side, the that signals a movement. The hand open downwards, the arm moves hand open downwards, the arm moves illustration shows "Load Slow Up".

  • Page 75: Safety When Servicing

    This section is a compilation of safety regulations which must be followed when checking and servicing the machine. Volvo CE disclaims any liability if tools, lifting gear or working met- hods are used other than those described in these operating ins- tructions.

  • Page 76: Read Before Servicing

    Modifications to the machine are not permitted. Please talk to your authorized Volvo CE dealer. When emptying/draining oil or fuel, collect the fluids in a suita- ble vessel. Spillage will damage the environment and may cau- se a fire.
  • Page 77 Safety when servicing Read before servicing Shut the engine down before opening the engine hood and oth- er covers. Make sure that no tools or other objects, which could cause damage, are left behind in or on the machine. Check that the equipment you are using for lifting or supporting parts of the machine, e.g.
  • Page 78 Safety when servicing Read before servicing make the floor slippery and are also dangerous in connection with electrical equipment or electric power tools. Oily or greasy clothes are a serious fire hazard. Check every day that machine and equipment, such as guards, are free off dirt and oil.
  • Page 79 Safety when servicing Read before servicing Working on surfaces with paint finish WARNING! When welding, grinding and torch cutting in the vicinity of spray painted surfaces, rubber or plastic parts extreme care should be exercised. The heating of paints and polymeric materials may generate health affecting and environmentally hazardous substances.
  • Page 80 Safety when servicing Read before servicing Fluorinated rubber Exercise extreme care when handling suspected fluorinated rubber. Certain seals, which have to withstand high operating temperatu- res (e.g. in engines, transmissions, axles, hydraulic pumps), may be made from fluorinated rubber, which, when exposed to strong heat (fire), forms hydrogen fluoride and hydrofluoric acid.
  • Page 81 Safety when servicing Read before servicing Measures to be taken after a fire When handling a machine which has been damaged by fire or the exposure to intense heat, the following protective measures be strictly observed must under any circumstances: –...
  • Page 82 Safety when servicing Read before servicing...

  • Page 83: Service And Maintenance

    Warranty inspection Two warranty inspections according to operating hours should be carried out in a workshop authorized by Volvo CE. The first at 50/ 100 and the second at 1000 operating hours. In order to keep the warranty valid all warranty inspections must be performed.
  • Page 84 Service and maintenance Cleaning the machine Clean the machine regularly with commercially available car cle- ansers in order to avoid damage to paintwork and other surfaces. IMPORTANT! Do not use strong chemical cleansing agents. This avoids damage to painted surfaces. NOTE! Daily cleaning of areas susceptible for the accumula- tion of dust, chips and other dirt reduces the fire hazard.

  • Page 85: Service Points

    Service and maintenance Service points Service points Counterweight The service points are accessible in the engine compartment be- hind the counter weight and under the hood on the right hand side. NOTE! After loosening the screws at the fastening points the left and right hand counterweights can be folded away from the machine.
  • Page 86 Service and maintenance Service points Service point in the engine compartment The service points can be accessed in the engine compartment. 1016531 1 Engine oil level 2 Engine oil filler neck 3 Engine oil filter 4 Fuel filler neck 5 Fuel prefilter / water separator 6 Fuel filter 7 Coolant compensation tank 8 Radiator...
  • Page 87 Service and maintenance Service points Service points under the right hand hood The service points for the hydraulic system components are loca- ted under the right hand hood. 1016528 13 Hydraulic oil level gauge 14 Hydraulic oil filler neck 15 Hydraulic oil tank 16 Hydraulic oil filter 17 Main control valve 18 Pressure accumulator...

  • Page 88: Engine

    Changing the engine oil Oil change intervals acc. to the number of operating hours, but at least once per year Type Operating hours EC35 1. Service after 100h, then every 500h. EC45 1. Service after 100h, then every 500h. 1016525 IMPORTANT! Change the oil at operating temperature and with the engine shut down.
  • Page 89 Changing the engine oil filter Oil change intervals acc. to the number of operating hours, but at least once per year Type Operating hours EC35 1. Service after 100h, then every 500h. EC45 1. Service after 100h, then every 500h. WARNING! Hot oil –...

  • Page 90: Fuel System

    In case of excessive contamination of the fuel the fusel tank can be drai- ned via the drain plug (under the left hand side of the frame). Type Filling capacity EC35 66 litre EC45 66 litre WARNING! When working on the fuel system do not use open fire.
  • Page 91 Service and maintenance Fuel system Changing the fuel filter Change the fuel filter every 500 operating hours, but at least once every year. 1 Close the fuel cock (5.1) on the fuel prefilter/water separator (5) by turning it one turn in clockwise direction. 2 Loosen the fuel filter with a filter wrench.

  • Page 92: Cooling System

    To be able to differentiate between the coolants apply the follow- ing: The cooling system is filled with Volvo Coolant VCS if – it is yellow – there is a decal at the filling point with the text “Volvo Coolant 11445056 VCS” (see figure). 1020820 The cooling system is filled with Volvo Coolant if –...
  • Page 93 NOTE! Change coolant every 2000 hours or every second year if the system is filled with Volvo Coolant VCS. NOTE! Change coolant every 2000 hours or every second year if the system is filled with Volvo Coolant.
  • Page 94 10 Fill up coolant in radiator (8) and compensation tank (7) up to FULL (MAX) mark on the compensation tank (7). NOTE! Check rubber hose and cap on compensation tank for leaks! Type Filling capacities EC35 6 litre EC45 6 litre WARNING! Dispose of collected coolant environmentally.

  • Page 95: Air Filter

    Service and maintenance Air filter Air filter If control light (7) in the instrument panel lights up the filter must be immediately cleaned or, if necessary, replaced. Check the air lines (filter - engine) for leaks during every main- 1011213 tenance.

  • Page 96: Electrical System

    Service and maintenance Electrical system Electrical system Safety regulations Work on the electrical system must only be performed by spe- cially trained persons and by using specified tools and test- ing equipment. The engine must be shut down and the battery disconnected be- fore attempting work in the electrical system of the machine.
  • Page 97 Service and maintenance Electrical system Battery The battery (11) is located at the right under the side covering. 1 To remove the battery, disconnect the negative terminal (-) first. To install the battery, connect the positive terminal (+) first. Any contact between a tool and the cable connecting the positive pole and the frame, may cause sparks.
  • Page 98 Service and maintenance Electrical system Charging the battery WARNING! During the charging process oxyhydrogen will develop inside the battery. A short circuit, an open flame or sparks in the vicinity of the battery can cause an explosion. The charging current must always be interrupted before remo- ving the charging clamps.

  • Page 99: Track Reduction Gear

    4 Screw drain plug (2) back in. 5 Fill in oil up to the overflow point of the level inspection bore (1). Type Filling capacities EC35 2 x 0.6 litre (2 x 60 in³) EC45 2 x 0.8 litre (2 x 60 in³) (For quality of gear oil please refer to the table of fuels and lubricants on page 107).

  • Page 100: Tracks

    Service and maintenance Tracks Tracks Checking the track tension Check and adjust the track tension every 10 operating hours WARNING! Incorrect tension reduces the lifetime of the tracks. A too low track tension increases the risk of the tracks jumping off.

  • Page 101: Hydraulic System

    Service and maintenance Hydraulic system Hydraulic system Checking the hydraulic oil level Check the hydraulic oil level every 10 operating hours. 1 Park the machine on horizontal ground. 2 Operate all cylinders to both directions while the engine is run- ning.
  • Page 102 (13), it must reach the middle of the sight glass (13.2); top up if necessary. 15.1 Type Filling capacities 15.2 EC35 62 litre EC45 62 litre NOTE! (Quality of hydraulic oil see table of fuels and lubri- cants on page 107). If the hydraulic system is filled with bio-...
  • Page 103 Hydraulic system Changing the hydraulic oil filter Check the hydraulic oil filter acc. to the operating hours. Type Operating hours EC35 1. Service after 100h, then every 500h. EC45 1. Service after 100h, then every 500h. 1012166 1 Operate all cylinders, until they are fully retracted (see Fig. B).
  • Page 104 Service and maintenance Hydraulic system Cleaning the radiator cooling fins Clean the radiator cooling fins every 250 operating hours. Always clean the cooling fins on radiator (8) and hydraulic oil coo- ler (10) by blowing out with compressed air from inside to outside. IMPORTANT! Preferably clean the radiator fins only with compressed air! Cleaning with water only when the engine is cold!

  • Page 105: Greasing The Bearings

    Service and maintenance Greasing the bearings Greasing the bearings The service life of bushings and pivot pins can be considerably ex- tended, by regularly greasing the machine in the correct way. Bearing lubrication has two main purposes: – To add grease to the bearing to reduce friction between pin and bushing.

  • Page 106: Lubrication And Service Chart

    Service and maintenance Lubrication and service chart Lubrication and service chart Inspection, oil change and lubrication intervals EC35/ EC45 Every: 10, 250, 500, 1000 and 2000 operating hours. 1011315 *See tabular overview.
  • Page 107 Service and maintenance Lubrication and service chart Position Measures every 10 operating hours Page General inspection (Oil, water and fuel leaks, machine components and hoses, fittings and hydraulic connections, function of control elements, working lights, control lights and diesel engine). Lubrication chart (see lubrication and maintenance plan) Checking the fuel level Check the coolant level...
  • Page 108 Service and maintenance Lubrication and service chart Position Measures every 500 operating hours Page Changing the engine oil Changing the engine oil filter Replacing the fuel prefilter / water separator Changing the fuel filter Replacing the air filter cartridge Auxiliary filter cartridge (option) Changing the hydraulic oil filter Check the hydraulic system pressure* Position...

  • Page 109: Specifications

    Other mineral oils can be used, if they comply with the recommended viscosity specifications and meet the quality requirements. The use of any other oil quality (e.g. biologically degradable oil) requires the approval of Volvo CE. If the hydraulic system is filled with biodegradable 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.
  • Page 110 (RME) is in some markets offered both as pure product or for mixing with diesel fuel. Volvo CE permits an additive quantity of max. 5% of bio-diesel to the diesel fuel, mixed in by the oil manufacturer.

  • Page 111: Coolant

    Specifications Coolant Coolant Use the same coolant as the system was filled with previously. To avoid damage to engine and cooling system, different coolants or corrosion protection must not be mixed. When using concentrated coolant and clean water, the mixture must contain 40–60 % concentrated coolant and 60–40 % clean water.

  • Page 112: Capacities, Change Intervals

    Specifications Capacities, change intervals Capacities, change intervals Filling capacities Litres EC35 EC45 Fuel tank Cooling system (complete) Engine oil including filter Hydraulic oil tank (tank and hydraulic system) Travel gear 2 x 0.6 2 x 0.8 Oil and fluid changes...

  • Page 113: Engine

    Specifications Engine Engine EC35 Designation VOLVO D2.2 Combustion method Diesel with direct injection system Engine power, net ISO 9249 26 kW / 34.8 PS at 2200/min Max. torque 140 kW at 1100 rpm Number of cylinders Bore x stroke 88 x 90 mm...

  • Page 114: Electrical System

    EC35: 12V x 55A EC45: 12V x 55A Starter motor EC35: 12V / 2.3 kW EC45: 12V / 2.3 kW Relays and fuses Relay and fuses are located under the driver's seat and on the rear side of the right hand operating console in the cab.
  • Page 115 Specifications Electrical system Relays and fuses (assignment plan) Relay under the driver's seat 1012178 Fuses in cab The fuse strip is located under the driver's seat. 1011312 Fuse strip on right hand control console (see also page 34). 10 11 1011311...
  • Page 116 Specifications Electrical system Relay No. Relay Relay function 1 R1 Engine preheating 2 R2 Starting the engine 3 R3 Working headlights/lighting system Fuses No. Lock Ampere Function 1 FU 20A 20 A Electric power supply for control unit 2 FU 20A 20 A Electric power supply for control unit 3 FU 5A 5 A Electric power supply for control unit, engine preheating relay...
  • Page 117 (main fuse) 4 audible war- Supply fault starter and 5A fuse defective FC1.03 ning signals preheating relay. WARNING! If the fault could not be remedied by application of the corrective measures you should consult your Volvo CE dealer.

  • Page 118: Power Transmission

    Specifications Power Transmission Power Transmission Travel system EC35 EC45 Travel speed 1. Gear: 2.8 km/h 1. Gear: 3 km/h 2. Gear: 4.3 km/h 2. Gear: 4.4 km/h Max. traction power 3630 daN 4080 daN Chassis braking system Primary brake Hydrostatic brake. If the levers of the chassis control are released, the machine will come to a halt.

  • Page 119: Slewing System

    Specifications Slewing system Slewing system Slewing system EC35 EC45 Slewing ring (ball bearing ring gear) with internal gearing and remote lub- rication. Slewing speed (directly driven 10 rev./min 10 rev./min Orbitrol hydraulic motor without reduction gear) Brake system for slewing gear Parking brake Automatic (interlocking of slewing superstructure spring friction brake).

  • Page 120: Cabin

    For this purpose the information in ISO/CEN Technical Report is recom- mended. To ensure that the whole-body vibration emission during machine use is kept to a minimum, see page 48. Sound information EC35 EC35 EC45 EC45...

  • Page 121: Hydraulic System

    Specifications Hydraulic system Hydraulic system EC35 Hydraulic pump 90 l/min. Bucket cylinder 54/35 l/min Dipper cylinder 64/43 l/min Boom cylinder 45/40 l/min Offset cylinder 23/15 l/min Dozer blade cylinder 38/29 l/min Travel movement left/right 60 l/min (one track) Optional equipment 60 l/min.
  • Page 122 Specifications Hydraulic system Cylinder EC35 Cylinder (mm) Bore-Ø (mm) Rod-Ø (mm) Stroke (mm) Bucket cylinder Dipper cylinder Boom cylinder Offset cylinder Dozer blade cylinder EC45 Cylinder (mm) Bore-Ø (mm) Rod-Ø (mm) Stroke (mm) Bucket cylinder Dipper cylinder Boom cylinder Offset cylinder...

  • Page 123: Weights

    Specifications Weights Weights (including operator with 75 kg) EC35 Version Rubber tracks 300 mm Steel tracks 300 mm Cabin 3540 kg 3582 kg Cabin 3422 kg 3464 kg EC45 Version Rubber tracks 400 mm Steel tracks 400 mm Cabin 4550 kg...

  • Page 124: Dimensions Ec35

    Specifications Dimensions EC35 Dimensions EC35 1012170 Dimensions (mm) The technical data of the machine serve for the purpose of information only and can be changed by the manufac- turer without prior notification. Version EC35 1400 1700 5025 5055 3400 3430...
  • Page 125 Specifications Dimensions EC35 1011314 Dimensions (mm) The technical data of the machine serve for the purpose of information only and can be changed by the manufac- turer without prior notification . Version EC35 1400 1700 4840 5020 3530 3720 3170...

  • Page 126: Dimensions Ec45

    Specifications Dimensions EC45 Dimensions EC45 1012259 Dimensions (mm) The technical data of the machine serve for the purpose of information only and can be changed by the manufac- turer without prior notification . Version EC45 1400 1700 5284 5286 3735 3794 5018 4875...
  • Page 127 Specifications Dimensions EC45 1011316 Dimensions (mm) The technical data of the machine serve for the purpose of information only and can be changed by the manufac- turer without prior notification . Version EC45 1400 1700 4929 5081 3522 3674 3454 3753 3619 3906...

  • Page 128: Nominal Lifting Loads Ec35

    Specifications Nominal lifting loads EC35 Nominal lifting loads EC35 Nominal lifting loads Europe Nominal lifting loads in kg, i.e. 75% of the tipping load or 87% of the hydraulic limit. These loads apply for the complete height (Z.) and for the specified reach. Increase of loads by 3% for steel tracks, except the marked values (* = hydraulic limits).
  • Page 129 Specifications Nominal lifting loads EC35 Nominal lifting loads Northern America Nominal lifting loads in kg, i.e. 75% of the tipping load or 87% of the hydraulic limit. These loads apply for the complete height (Z.) and for the specified reach. Increase of loads by 3% for steel tracks, except the marked values (* = hydraulic limits).

  • Page 130: Nominal Lifting Loads Ec45

    Specifications Nominal lifting loads EC45 Nominal lifting loads EC45 Nominal lifting loads Europe Nominal lifting loads in kg, i.e. 75% of the tipping load or 87% of the hydraulic limit. These loads apply for the complete height (Z.) and for the specified reach. Increase of loads by 3% for steel tracks, except the marked values (* = hydraulic limits).
  • Page 131 Specifications Nominal lifting loads EC45 Nominal lifting loads Northern America Nominal lifting loads in kg, i.e. 75% of the tipping load or 87% of the hydraulic limit. These loads apply for the complete height (Z.) and for the specified reach. Increase of loads by 3% for steel tracks, except the marked values (* = hydraulic limits).

  • Page 132: Attachments

    Specifications Attachments Attachments Bucket EC35 Content (l) Content (l) Coupling type Tooth Weight (kg) (struck) (heaped) 62,8 82,3 111,5 41,5 62,4 1300 1300 STD: Standard coupling / manual fastening QC: Quick coupling / quick fastening AT: Bucket teeth with adapter and locking element...
  • Page 133 Specifications Attachments Hammer EC35 Weight Type Coupling type Hydraulic oil flow (l/min) Hydraulic pressure (bar) (kg) HB260 HB260 EC45 Weight Type Coupling type Hydraulic oil flow (l/min) Hydraulic pressure (bar) (kg) HB260 HB260 Hammer tools Type Pointed chisel (A) Flat chisel (B)

  • Page 134: Service History

    Specifications Service history Service history Type of maintenance Signature and stamp Maintenance after 50 hours Date Hours Warranty inspection Type of maintenance Signature and stamp Maintenance after 100 hours Date Hours Warranty inspection Type of maintenance Signature and stamp Maintenance after 500 hours Date Hours Service and maintenance...
  • Page 135 Specifications Service history Type of maintenance Signature and stamp Maintenance after 2500 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 3000 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 3500 hours Date Hours Service and maintenance...
  • Page 136 Specifications Service history Type of maintenance Signature and stamp Maintenance after 5500 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 6000 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 6500 hours Date Hours Service and maintenance...
  • Page 137 Specifications Service history Type of maintenance Signature and stamp Maintenance after 8500 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 9000 hours Date Hours Service and maintenance Type of maintenance Signature and stamp Maintenance after 9500 hours Date Hours Service and maintenance...
  • Page 138 Specifications Service history...
  • Page 139 Lubrication and service chart......... 81, 104 Cab equipment...............33 Measures before operation..........40 Cabin..............33, 118 Nominal lifting loads EC35........... 126 Capacities, change intervals ........110 Nominal lifting loads EC45........... 128 CE marking, EMC directives ..........7 Operating in uneven terrain or on slopes....... 51 Changing the engine oil filter .........87...
  • Page 140 Alphabetical index Ref.No. VOE21B1002144 English Printed in Sweden Volvo, Eskilstuna...

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Ec45

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