Professional Documents
Culture Documents
1.volvo Safety and Environment
1.volvo Safety and Environment
1.volvo Safety and Environment
'
CONTEN,.
A Safety and Environment
o General
1 Service and maintenance
3 Electrical and Information
Systems
5 Brakes
9 Hydraulic system
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Foreword
A35F/A35F FS/A40F/A40F FS
This service manual contains safety instructions,
specifications. service and maintenance instructions, as
well as diagrams.
Service on the machine should not be completed before
reading the instructions in the section "Safety".
I
Safety A)
The instructions are to be used by experienced mechanics
who have the necessary training for and experience of
these machines. The instructions are valid on the
conditions that work is done in a workshop, indoors, on a
solid and flat concrete floor. The workshop shall be
I General 0)
provided with adequate lighting and compressed air
equipment. as well as lifting devices with lift capacities
adapted to a majority of the work done on these machines.
21 A1 006587
Content, Service Manual
Folders Description binder Ref. no.
Binder kit (1 binder) 21A1006581
1 S Safety and Environment - 9 Hydraulic system 20024448
Content, binder
Flap Description/booklet Ref. no.
- Foreword 21A1006587
S Safety and Environment 21A1006589
o General, specifications 21A1006582
1 Service and maintenance 21A1006583
3 Electrical and information systems, diagrams 21A1006584
5 Brakes, diagrams 21A1006585
9 Hydraulic system, diagrams 21A1006586
WLVO CONSTRUCTION EQUIPMENT
SERVI[E MANUAL
A35F/A35F FS/A40F/A40F FS
CONTENT
A Safety and Environment
191 Safety and Environment
Foreword
This booklet is part of a complete service manual. Read the
foreword in the service manual.
A WARNING
Always read the booklet Safety before proceeding.
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Table of contents
19 GENERAL
191 Safety equipment. without own function group
CE-marking, EMC-directive ........................................................................ 5
CE-marking ............................................................................................... 5
The EU's EMC-directive ........................................................................... 5
EU's noise directive .................................................................................. 6
Cab roll-over protection (ROPS and FOPS) ............................................. 6
Safety concerns everybody! ....................................................................... 6
Safety when handling the machine ............................................................. 7
A few safety rules ..................................................................................... 8
Alternative exit ........................................................................................ 10
Service position 1 ..................................................................................... 12
-
Service position 2 ..................................................................................... 14
Without axle stand .................................................................................. 14
Service position 3 ..................................................................................... 17
With axle stand ....................................................................................... 17
Checking function ..................................................................................... 20
Safety-related electrical system .............................................................. 20
3
Decontamination ....................................................................................... 35
Decontamination after leaks/spills .......................................................... 35
Decontamination after accident .............................................................. 35
Decontamination after fire .................... ................................................... 36
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4
STANDARD PARTS, SERVICE
19 GENERAL
-
CE-marking
(Declaration of Confonnity)
NOTICE
Declaration of Conformity and CE-marking are only valid within
The person making any changes that affect machine safety is also
responsible for the same.
5
A machine or device must meet the requirements to be CE
marked. Our machines have been specifically tested for
electromagnetic interference. The machine's CE-marking and the
declaration of conformity also cover the EMC directive.
6
The Operator's Manual must always be kept in the cab for easy
reference.
Those who do not follow the safety instructions and observe the
warnings in this manual must make sure that their work method
WARNING SYMBOL
e the machine has been used correctly and has been maintained
according to recommendations in the service manuals and the
machine's Operator's manual.
prescribed service and inspections have been performed at the
specified intervals.
•
lubricant recommendations in the manual have been followed .
no safety seals have been opened by an unauthorized person.
all modifications and repairs have been performed in the manner
prescribed by Volvo.
only genuine Volvo parts/accessories, or attachments that fulfil
Volvo's requirements have been used.
7
Machine operators must have sufficient skills and knowledge of
the content in the operator's manual before operating the
machine.
It is important that the operator reads and follows the instructions
in the machine's operator's manual.
An untrained operator may cause serious injuries and fatalities.
Never operate a machine for which there is no Operator's Manual
available.
Learn to understand the warning plates, symbols and operating
instructions for the machine before you start operating.
General
- Repair malfunctions or defects that affect safety as soon as a
possible. •
- Always wear a hard hat, protective goggles, gloves, work
shoes and other safety items that your work requires.
- Avoid standing in front of or behind the machine, and on or a
under the machine when the engine is running. •
- To avoid unnecessary climbing on the machine, use a window
scraper or brush with long handle when cleaning external
window glass or rear-view mirrors.
- When servicing the machine, Le. changing light bulbs, a ladder
may be needed.
- Make sure that stepping surfaces, service areas, handles and
slip-protection are clean and free from oil, diesel fuel, dirt and
ice and that they're replaced if they are defective or missing.
- Check at regular intervals that all slip-protection is firmly
attached. If not, these shall be attached or replaced.
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A1710500
Fig.2 Entering/leaving the machine
8
- Always face the machine and use the steps and handrails when
entering or leaving the machine. Use two hands and one foot,
or two feet and one hand. Do not jump!
Before operating
- Read the Operator's manual before you operate the machine!
Follow the instructions for operating and perform the indicated
recommended actions before operating.
Some important rules below:
- Perform a control light test before starting the engine by turning
the ignition key to position 1 (see Operator's manual).
- Perform all safety checks prescribed in the Operator's manual.
~'"-
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.~ Never operate the machine if you are tired or under the
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influence of alcohol, medicine or other drugs.
I·e - Step only on the prepared non-slip surfaces and use the
provided handles and rails.
Hip-type seatbelt
9
When the engine is running
- Respecter symbols and alarm displays. The red alarm displays
require immediate action or consideration, see instructions in
the Operator's Manual under information display unit.
- Move the gear selector to neutral position and apply the parking
brake before leaving the machine.
- Do not stand near the frame joint unless it has been locked with
the frame joint lock.
- Stop the engine before you leave the machine unattended.
u Alternative exit
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V1092803
Fig.5
1 Alternative exit (right side of cab)
2 Hammer
10
NOTICE
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It is only possible to break windows marked with decal for
alternative exit.
Fig.6 - cut the seatbelt with the knife located in the rear edge of the
hammer.
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11
Service position 1
Applies to models: A35F (37142), A40F (37535)
Tools:
88830046 Dump body support
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Fig.7
A\;
Risk of crushing.
••••
An unlocked raised dump body can fall down. Personnel standing
under a falling dump body could be seriously injured, including
death. "
Always lock the dump body before entering under it.
3 Lock the steering joint with the steering jOint lock. Lower the
load body against the frame or elevate the load body and
secure with the load body lock or 88830046 Dump body
support.
4 During on-going service work, fasten a warning sign on the
steering wheel with information that service is in progress.
5 Turn off the engine and remove the start key.
6 Block the wheels in a suitable manner (Le. with wedges).
12
,
"UMOP IOO~ Ol aU!4~BW a4l MOil\! 9
"8Se8j8J 8JnSS8Jd 'W81S~S
:J!jneJP~H '006 pUB 8JnSS8Jd 8A8!j8J 'W81S~S 8>/eJ8 'OZ£
aas "S>jUBl aJnssaJd pUB sau!I paZpnssaJd aZpnssaJdaa L
Service position 2
Applies to models: A35F FS (37141), A40F FS (37534)
Tools:
88830046 Dump body support
14290266 Hose
t
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Fig.8
1 The 'Full Suspension' machine must be in the lowered
position. The machine shall be lowered when 20 metres A"
.~
remain to the service site. See 720, Relieve pressure.
2 Place the machine on firm and level ground.
3 Apply the parking brake.
14
Risk for personal injury caused by crushing. The machine could
tum. Lock the steering lock.
Risk of crushing.
An unlocked raised dump body can fall down. Personnel standing
under a falling dump body could be seriously injured, including
death.
Always lock the dump body before entering under it.
4 Lock the steering joint with the steering joint lock. Lower the
load body against the frame or elevate the load body and
secure with the load body lock or 88830046 Dump body
support.
NOTICE
Even if the machine has stopped lowering, it is not certain that the
system is pressureless. The pressure may still be maintained by
the accumulators.
t V1Q79621
15
10 For work in the FS hydraulic trailer circuit, make sure that
depressurizing has been performed by connecting two
14290266 Hose to the pressure check connections on the
accumulator bank's distribution block in the trailer frame.
Drain the oil into a suitable container.
11 Allow the machine to cool down.
1 VI049674
,
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16
Service position 3
Applies to models: A35F FS (37141), A40F FS (37534)
Tools:
88830046 Dump body support
14290266 Hose
t
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1 Place the machine on firm and level ground.
2 Apply the parking brake.
17
Risk for personal injury caused by crushing. The machine could
tum. Lock the steering lock.
Risk of crushing.
An unlocked raised dump body can fall down. Personnel standing
under a falling dump body could be seriously injured, including
death.
Always lock the dump body before entering under it.
3 Lock the steering joint with the steering joint lock. Lower the
load body against the frame or elevate the load body and
secure with the load body lock or 88830046 Dump body
support.
4 Raise the machine to top position, see 720, Forced Raising!
lowering, Full suspension.
t
1 5 Place the two axle stands with E-tool no. 2500 at the front
on the axle, see 080, E-2500.
t
V1079397
6 Place the 4 axle stands blocks with E-tool no. 2501 on the
front and rear bogie axle, see 080, E-2501.
A Front bogie axle, height of support: 192 mm (7.56 in) t
B Rear bogie axle, height of support: 218 mm (8.58 in)
7
8
Lower the machine on the axle stands with the keypad, see
120, Forced Raising/lowering, Full suspension.
Depressurize pressurized lines and pressure tanks. See
520, Brake system, relieve pressure and 900, Hydraulic
system, pressure release.
.t
A"
V1079398
Fig.13 Right side, trailer
1 Axle stand, E-tool no. 2501, A. Front
2 Axle stand, E-tool no. 2501, B. Rear
18
9 Depressurize the system by forced lowering using the
[ill8~OO
10 During on-going service work, fasten a warning sign on the
steering wheel with information that service is in progress.
11 Turn off the engine and remove the start key.
@]\§wB 12 Block the wheels in a suitable manner (i.e. with wedges).
§O[§]O
Vl091529
Fig.14 Keypad
NOTICE
Even if the machine has stopped lowering, it is not certain that the
t system is pressureless. The pressure may still be maintained by
the accumulators.
V1079621
Fig.15 Pressure check connections on tractor
under cab (can be reached under cab door)
1 Pressure check connection
t
1 V 1049674
19
Checking function
Filters
Oil and fuel filters shall be drained and put into sealed containers
before they are left for destruction.
Refrigerant R 134a
Refrigerant R 134a contains substances that affect the
greenhouse effect and may never be released into the open air.
Shall be recycled according to instructions in separate component A
manual for the air conditioning. .,
Batteries
_ 1 , v\ 'lk\l'~"'~l:'~~~~K~~
~_,?_ ~ I J" r. ""':.-t""
J- !~\ 'c
•
Batteries contain environmentally hazardous substances and
corrosive acid. Shall be left for recycling.
V1033092
Fig.17 Corrosive acid
20
Chemicals
Chemicals, paints, glue, cleaning agents, etc. shall be left for
recycling and destruction.
Electronics
Electrical and electronic waste, e.g., circuit boards and bulbs,
shall be left for recycling.
When heated, rubber and plastics can give off substances that
are hazardous to personal health and the environment.
21
- Be careful when handling machines that have been exposed
to fire or other intense heat. See also Checklist after a fire or
heat exposure page 32
- Always use gloves, protective clothing, safety goggles, and
breathing protection.
Fluor rubber
NOTICE
In case of contact with hydrofluoric acid, it may take several hours
before any symptoms appear.
Decontamination
The area around a heated machine part that is suspected to be
made of fluor rubber shall be decontaminated by thorough and
ample washing with lime water (a solution or suspension of
calcium hydroxide. that is, slaked lime) in water. After completing
the decontamination work, wash the gloves in the lime water and
then discard them.
If the machine has been exposed to a fire or other intense heat.
the safety actions in the followi(1g checklist shall be followed
22
unconditionally at all times: Checklist after a fire or heat
exposure page 32
Asbestos information
The components in Volvo Construction Equipment's machines
are free from asbestos, that is why it is important to use genuine
Volvo spare parts.
•
when working with repairs and maintenance of the air
conditioning. Therefore, read and consider the safety section in
the Service Manual Air Conditioning R134a before starting any
work.
For repairs of the air conditioning, refer to the Service Manual Air
e Conditioning R134a.
NOTICE
The jack must always be relieved of weight bearing with axle
stands under the raised axle before the wheel is removed!
e publication.
- If a jack is to be used, make sure that the ground or floor is
even and is sufficiently firm or strong to support the expected
load.
23
Safety when using lifting equipment
- All lifting devices, e.g., slings, straps, ratchet blocks, etc., must
meet governing national regulations for lifting devices.
We will not accept any responsibility if other lifting devices,
tools or work methods are used, other than those described in
this publication.
- Make sure that the ground surface is flat and has sufficient
strength to support the expected load for lifting device with
load.
Fig.18 Do not overload lifting or support equipment. _ When lifting or supporti ng machine parts! use equipment with
a lifting capacity that at least equals the weight of the part in
question.
t
- Use the lifting eyes or lifting points that are located on certain
machine components.
. 'f\WAV,f.'.~~~~~JJ~~
Make sure that you stand off to the side of the tyre when inflating
a tyre mounted on a split rim. Wheels of this type may explode,
causing personal injury and even death.
Use a self-attaching air-chuck with a hose long enough to allow
you to stand outside the danger area when inflating a tyre.
Inflating
- Always stand to the side of the tire when inflating a tire installed
on a split rim. Use a self-locking nozzle with a hose that is long
enough to allow you to stand outside of the hazard zone during
inflation, see figure.
Spare tyres should only be inflated with enough air to keep the
rim parts in place.
t
Use an inflation cage, safety cables or chains to secure a loose
wheel when inflating it with air.
The machine should be without load when checking the tyre
pressure. t
A1710400 Installing tyres and rims
Fig.19 Always stand off to the side of the tyre when - Never fit a tyre on a rim if the tyre is not clearly recommended
inflating it with air. for that rim.
- Never assembly rim parts for different dimensions and never
use damaged or defective parts.
- Be careful if you are using reconditioned wheel parts. Defective
or incorrect welding, heating or soldering may have weakened
the parts and could result in future failure.
- Make sure that the lock ring groove in the rim is free from dirt
and rust before fitting the lock ring.
24
- Be careful when working with bead-breakers and hydraulic
jacks. Keep outside the danger area when removing foreign
objects from the tire tread. A bead-breaker that disengages
releases with enough force to cause severe personal injuries,
even death.
Explosion hazard.
•
with eyes, skin or clothes. Wear protective equipment. Electrolyte
splashes in eyes must be rinsed off with water immediately.
Electrolyte on skin must be washed off with soap and water
immediately. Seek medical advice.
•
Batteries contain sulphuric acid, which is highly corrosive on the
human body and on machine parts. Also, batteries generate
hydrogen gas when they are loaded or charged. Hydrogen gas
and the oxygen in the air generate so-called oxy-hydrogen gas,
which is very explosive.
•
electrolyte may leak out.
- Do not connect a discharged battery in series with a fully
charged battery. Explosion hazard!
- Make sure that metal objects (such as tools, rings, watch
straps, etc.) do not come into contact with the battery terminals.
Personal injury and fire may result.
- Always cover the top of the batteries with a cloth or other non
conducting material when working close to the batteries.
- Always refit the terminal caps on the batteries.
- Batteries contain substances that are hazardous to health and
the environment. Therefore. discarded batteries must be
disposed of according to applicable local/national regulations.
25
Charging of batteries
Explosion hazard.
A CAUTION
The booster batteries or any other power source must have the
same voltage as the batteries on the machine.
NOTICE
A battery charger with mains power supply (connected/turned on)
may never be connected to the machine's batteries when trying
to start the engine since this may damage the machine's 6
Fig.20 electronic system. .,
1 Connecting batteries in series
2 Connection, (+) terminal on battery
3 Connection, grounding point on machine
26
1 2 Connect two 12 V batteries in series. (+) terminal on one
battery to H terminal on the other.
V1092342
e Fig.21
1 Cable connection to (+) terminal
e
the machine's battery and the booster battery's (+) terminal.
4 Connect the other start cable between the booster battery's (-)
terminal and the grounding point on the machine. The
grounding point is located between engine and radiator as
shown in adjacent figure.
S Connect the machine's batteries by turning on the electric
power with the battery disconnector.
6 Wait a few minutes and then start the engine with the start key
in the cab.
7 When the engine has started, wait a few minutes and then
remove the start cable from the grounding point on the
machine and then the start cable's clamp from the booster
battery's H terminal.
8 Then remove the start cable between the (+) terminals.
9 Refit the terminal caps on the battery terminals.
10 Put back the rubber protection over the batteries and close the
cover.
e Fig.22
1 Grounding point on machine
27
- Remember the fire hazard!
~., V1069801
Make sure that the person working with pressurized systems has
the right training. the right equipment. and follows the safety rules.
Those who follow the simple rules below have laid a good
foundation for avoiding accidents.
General
- Never adjust a pressure limiting valve to a higher pressure than
that recommended by the manufacturer.
- A hydraulic hose that swells. e.g .• at a connection, shows that
it is about to rupture. Replace the hose as soon as possible!
Pay attention to leaks from hydraulic hoses and connection.
Repair the leak before the part ruptures!
- Discarded pressure accumulators shall be punctured before ..
they are scrapped to avoid the risk of explosion. see Safety "
when handling accumulators page 29.
28
Leaking high-pressure hydraulic hoses may cause severe
injuries. Fine jets have high penetrating capacity on bare skin.
- When checking for leaks, use paper or a stiff board. Never use
your hand.
•
from the machine, so-called precharge pressure. Therefore, be
very careful during all handling and work with accumulators.
?;'@\\Vk'l7!:\g)~_Uj~
.8 7' {"~J
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(~~,
:~~. -~~
A discarded accumulator which is not punctured may still contain
high pressure and must always be handled with great care.
29
Safety during electric welding
A CAUTION
Before starting any electric welding, disconnect the battery
connections. All connections to the control units (ECU) should be
disconnected. Connect the welding unit's ground cable as close
as possible to the welding point.
NOTICE
Take extra care if a high-pressure washer is used for cleaning
since the water jet may damage electrical components and cable
e
insulation, even at moderate water pressures and temperatures.
Protect electrical cabling in an appropriate manner. The engine
and battery disconnect switch should be turned off.
e
General
- There is always a risk of fire. Find out what type of fire
extinguisher to use, where it is located and how to use it.
30
- Fire-fighting equipment installed in or on the machine must be
maintained in working order. This equipment should be
regarded as a complement to the operator's own efforts in case
of a fire.
The equipment must not be regarded as a substitute for the
operator's own fire-fighting efforts.
- A fire extinguisher installed on the machine or used when
working on the machine should be of an approved type.
- At the slightest sign of fire, if the situation allows it and keeping
your own safety in mind, take the following action:
- drive the machine away from the fire hazard and danger area
- lower the load body onto the frame
- turn off the engine
- leave the cab
- turn off the electric power with the battery disconnect switch
•
- start putting out the fire and call the fire department if
necessary.
A1712100 - Smoking or open flames are absolutely forbidden in the vicinity
Fig.24 The fire extinguisher is located directly to the of machines when refuelling or when the fuel system is open
right inside the door in the cab. to contact with the air.
Cleanliness
•
- Cleanliness is of decisive importance for the trouble-free
operation of the machine and the reliability of machine
systems. For this reason, keep the area clean where service
work is performed. Oil and water make floors and steps slippery
and are also dangerous in connection with electrical systems
•
and electric power tools. Oily clothes constitute a serious fire
hazard.
- Check daily that the machine and equipment, Le., underbody
skid plates, are free from dirt and oil. This reduces the fire
hazard and makes it easierto detect defective components and
loose parts.
,.&;':.~:i..,I,lr· 10'N'
:~,:.',Yf;\~('~.:"·.·: :.. :'.~
If a high-pressure washer is used when cleaning, work
carefully since damage may be caused to electrical
components and insulation of the electrical cabling even at
relatively moderate water pressure and temperature. Protect
electrical cabling in a suitable manner.
31
Electrical system
- Check electrical cabling for chafing damage and make sure
that they cannot be damaged in such a way. This applies
especially to unfused leads, which are coloured red.
For example, electrical cabling between:
- Batteries
- Battery - starter motor
- Alternator - starter motor
- Electrical cabling to the engine's preheating coil.
If unfused leads are disconnected, it is important to check that
they are reconnected and clamped in such a way that the risk
of chafing is eliminated. Unfused leads must not rest against
oil or fuel hoses.
If connectors have been unplugged from a control unit, both
the plug and socket should be clean and dry before they are
reconnected.
When installing any optional equipment, make sure that all
electrical cabling is connected across a fuse and that they are
routed and clamped in such a way that there is no risk of
t
chafing.
A CAUTION
A fire extinguisher should be easily accessible during all
welding work.
- When performing electric welding on the machine, the battery
cables must be disconnected and the connectors unplugged
from the control units.
- Never weld on a painted surface without first having removed
the paint. Welding on a painted surface not only causes health
f
hazardous effects but also results in technically inferior welds,
which in the future could lead to failures and subsequent
accidents.
32
water (a solution or a suspension of calcium hydroxide, i.e.
slaked lime).
Use thick, protective gloves made of rubber and wear goggles
that are certain to protect your eyes.
- Seek medical attention if your skin may have come in contact
with burnt fluor rubber. The skin should be treated with
Hydrofluoric Acid Burn Jelly or similar.
Symptoms may not appear until several hours after contact
with burnt fluor rubber.
- Discard protective gloves, rags and other items that may have
come into contact with burnt fluor rubber.
- Ensure good ventilation during the work.
- In case of splash in eyes: rinse immediately with plenty of water
for at least 15 minutes. Contact a doctor.
• Environment
•
. due to ever-increasing industrialization worldwide. Nature,
animals and humans all over the world are exposed daily to great
risks in connection with different ways of handling chemicals.
There are still no oils and coolants, etc. on the market that are
completely unharmful to the environment. Therefore, all who
handle, perform service on or repair vehicles must use the
assistive devices and methods that are necessary for performing
their work in an environmentally correct manner.
Recycling
- Contribute to careful utilization of natural resources by
depositing scrapped materials with recycling or destruction
companies.
• Batteries. etc.
- Components like batteries, plastic objects and other potentially
environmentally hazardous waste may not be discarded just
anywhere or anyhow. Such waste must be handled in an
Oilslfluids
- Oils that are freely released cause environmental damage and
can also start fires. When draining/emptying oils or fuel,
suitable action must be taken to prevent unnecessary spills.
- Waste oils/fluids must always be taken care of by an authorized
company.
- Watch for any oil leaks or leakage of other fluids! Repair the
leak immediately.
33
into the atmosphere. Special training is required for all service
work on the air conditioning system. Many countries also
require certification by an official authority for such work. See
Safety when working with air conditioning refrigerant
page 23.
Fig.25
Waste handling
34
Environmentally hazardous fluids
Pay attention to leakage of fuel, oils and other fluids from the
machine that may contaminate the environment.
• Air conditioning
Refrigerant R134a contains substances that affect the
greenhouse effect and may never be released into the open air.
•
Service personnel who work with refrigerants must know the laws!
rules that apply in the local country but also international rules.
Decontamination
•
Start decontamination as soon as possible. Certain substances
spread quickly in the environment.
35
Isolate the leakage area using banks drain booms.
Stop leaking fluids so that they do not drain into rain water/storm
water drains or ditches.
Collect the absorbent materials and the top layer of soil, put it into
sealed containers for transport to destruction.
NOTICE
Pay attention and be aware that certain substances may be
poisonous after a fire. See Health hazards with paint, plastics and
rubber page 21.
e
See also Checklist after a fire or heat exposure page 32.
36
USER FEEDBACK
To From
Volvo Construction Equipment AS
Customer Support Division
Dept. 45110, RLA 0301
SE-631 85 Eskilstuna
Sweden
e-mail: servicemanuals@volvo.com
• Ref no:
Page no:
Suggestion/Reason why:
•
•
Date: ............................................................ .
Name: ........................................................... .
I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
, ................................................................................................................................................................................. .
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