Volvo EC330B Operator's Manual
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Volvo EC330B Operator's Manual

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OPERATOR'S MANUAL
EC330B
Volvo Construction Equipment
Ref. No. : VOE 2134355130
English
Printed in Sweden
KOR

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Summary of Contents for Volvo EC330B

  • Page 1 OPERATOR’S MANUAL EC330B Volvo Construction Equipment Ref. No. : VOE 2134355130 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: Operating Instructions

    EC330B OPERATOR’S MANUAL Foreword This Operator 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 Contents out any preventive maintenance. Keep the manual in the intended place in the cab so that it is always at hand.

  • Page 4: Handling And Maintenance Of The Machine

    – all modifications and repairs performed, and methods used, have been prescribed by Volvo. – only Volvo genuine spare parts/accessories, or genuine spare parts/accessories which meet Volvo’s requirements, have been used. WARNING!

  • Page 5: Communication Equipment, Installation

    IMPORTANT! All installation of optional electronic communication equip- ment must be performed by trained professionals and in accordance with Volvo Construction Equipment instructions applicable to the specified machine. Protection from electromagnetic interfer- ence This machine has been tested in accordance with EU directive 89/ 336EEC governing electromagnetic interference.
  • Page 6 Forewor Communication equipment, installation...

  • Page 7: Table Of Contents

    Contents Contents Forewor ..............1 Communication equipment, installation ........ 3 Contents ..............5 Presentation ............7 General ................. 7 Plates and decals ............... 10 Service ................24 General information ............25 Instruments and controls ........29 General ................29 Overview ................30 Description of instrument panel ..........

  • Page 8: Contents

    Contents Safety when servicing ........119 Introduction ............... 119 Service position ..............120 General ................121 Handling lines, tubes and hoses ........123 Measures to prevent fire ........... 124 Batteries ................128 Air conditioning ..............130 Use handholds and steps for climbing on / off ....132 Service and maintenance ........

  • Page 9: Presentation

    The engine is a straight six-cylinder, four stroke, direct injection diesel with 9.6 liter cylinder volume, turbo charged, intercooled and electronic controller fuel injection, EMS (Engine Management System) with a cast iron block and cylinder head. Volvo engine D12CECE2 Electrical system...
  • Page 10 Presentation General Main control valve The control valve consists of two 5-spool blocks and an intermedi- ate block connected by screws. They contain six main spools for digging units, three spools for conflux and straight travel, a spool for the option unit, a main relief valve, port relief valves, holding valves and check valves.

  • Page 11: Ce Marking And Declaration Of Conformity

    CE marking and the issue of a new Decla- ration of Conformity in compliance with the EU Machine Safety Directive. Volvo Construction Equipment is only responsible for a ma- chine which is used with approved equipment and spare parts specified by Volvo Construction Equipment.
  • Page 12 Identification Number (PIN) should be stated. Volvo Construction Equipment Volvo Construction Equipment Volvo Construction Equipment Volvo Construction Equipment Korea Ltd. Volvo Construction Equipment Korea Ltd. Volvo Construction Equipment Korea Ltd. 1, Guehyun-Dong, Changwon-City, Kyungnam, Korea 641-430 1, Guehyun-Dong, Changwon-City, Kyungnam, Korea 641-430...
  • Page 13 Presentation Plates and decals 3 The quickfit nameplate is attached on the outside of the quick- fit. (shows part number and weight) 4 The bucket nameplate is attached on the top of the bucket. (shows the bucket model order Number, serial number, bucket part number, rated capacity, weight, cutting width, tooth part number and adapter part number)
  • Page 14 Presentation Plates and decals Information and warning plates The following depicts various warning and information texts that may be affixed to the machine and their mounting location. The op- erator must know and pay attention to the warning and safety in- formation on each decal and plate.
  • Page 15 Presentation Plates and decals 4 Emergency exit See The emergency hammer (B) should be used in emergen- cy situations for: on page 65. S80954 5 Warning, high voltage See Never operate close to a high tension power line on page S80602 6 Warning when operating the optional attach- ment...

  • Page 16: Plates And Decals

    Presentation Plates and decals S84243 8 Lifting capacity table Shoe 600 mm (kg) Pressure 34.34 MPa (350 bar) 5800 kg 6.45 m S84241 S84240C 0.0 m 1.5 m 3.0 m 4.5 m 6.0 m 7.5 m 9.0 m Maximum ∗8870 7.5 m 7040 ∗10780...
  • Page 17 Presentation Plates and decals Shoe 23.6 in (lb) Pressure 34.34 MPa (350 bar) 12790 lb 21' 2" S84241A S84240D 0.0 ft 5.0 ft 10.0 ft 15.0 ft 20.0 ft 25.0 ft 30.0 ft Maximum ∗20050 ∗19670 25 ft 19990 15890 ∗23460 ∗18980 20 ft...
  • Page 18 Presentation Plates and decals S84243 Shoe 31.5 in (lb) Pressure 34.34 MPa (350 bar) 12790 lb 21' 2" S84241A S84240E 0.0 ft 5.0 ft 10.0 ft 15.0 ft 20.0 ft 25.0 ft 30.0 ft Maximum ∗20050 ∗19670 25 ft 20490 16310 ∗23460 ∗18980...
  • Page 19 Presentation Plates and decals Shoe 600 mm (kg) Working conditions: – With no tool (bucket, clamshell.). If object handling is performed with tool installed, the weight of the tool shall be deducted, the weight of the tool shall be – With retracted bucket cylinder. –...
  • Page 20 Presentation Plates and decals S82283E 9 Cab door window breakage WARNING S82002 10 Lubrication and service chart See Lubrication and service chart on page 172. S83013 11 Warning for rotating parts S80605A...
  • Page 21 Presentation Plates and decals 12 Do not smoke during fueling S80607 13 Battery See Batteries on page 128. Risk for explosion, corrosive burns and electric shock. S80721 14 Optional pedal See Optional pedal position on page 56. S82300A 15 Position of checking hydraulic oil level ISO VG #46: Standard ISO VG #32, VG #68: Option See Recommended lubricants on page 177.
  • Page 22 Presentation Plates and decals 19, 20 S82284A 16 Battery position S82035 17 Anchoring lug Towing is prohibited. See Transporting the machine on page 77. S80719 18 Read the operator’s manual S80598 19 Warning, hot and pressurized coolant S80715...
  • Page 23 Presentation Plates and decals 20 Warning for rotating and/or hot parts S80605 21 Lifting point for lifting the machine See Lifting machine on page 83. S80717 22 Locking the front window S80601 23 Handling accumulator WARNING See Handling accumulator on page 160. S80718 24 Risk of fire when fueling Shut off in case of fire...
  • Page 24 27 Read the operator’s manual before operating WARNING quickfit See Hydraulic quickfit (s1) (option) on page 87. If other working attachments are required or for more infor- mation, please contact your Volvo dealer. S80471 28 Do not step or walk S80720...
  • Page 25 Risk for crushing! S80596 31 Machine rigging EC460B 40 ~ 150 1.6 ~ 5.9 1.4 ~ 4 47.3 1200 47.2 28.6 See Lifting machine on page 83. EC360B -40 ~ 60 -1.6 ~ 2.4 45.9 1050 41.3 27.9 EC330B S82003C...

  • Page 26: Service

    Therefore, two warranty inspections should be carried out. The first after 100 operating hours and the second at 1000 operating hours. The times for these inspections may be changed by Volvo Con- struction Equipment without prior notice. Maintenance service Condition test and maintenance programme...

  • Page 27: General Information

    Federal Standards. Customer Assistance Volvo CE 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 believe you are entitled under the Emission Control System Warranty, you should contact your nearest Volvo CE Regional office for assistance.

  • Page 28: Normal Non-Road Engine Use

    Volvo CE recommends that the purchaser use the service pro- gramme for the non-road engine, known as Preventive Mainte- nance, including the recommended engine emission control maintenance.

  • Page 29: Preventive Maintenance

    The diesel fuels recom- mended for use in Volvo engines should meet ASTM designation: D975 No. ID (C-B) or No. 2D (T-T); with a cetane level above 42 and sulphur content not exceeding 0.5 percent by weight.
  • Page 30 Presentation General information...

  • Page 31: Instruments And Controls

    Instruments and controls General Instruments and controls General WARNING! Do not operate the machine before you learn the position and function of instruments and operating controls and completely understand how they are used! Carefully read through the following section, and also the chapter on Operating Instructions.

  • Page 32: Overview

    11 Overload warning lamp (option) 12 Quickfit lamp (option) 13 Hour meter indicator 14 Central warning lamp 15 Left/Right turn signal lamp (not applicable on EC330B) 16 Hammer selecting indicator lamp (option) 17 Shear selecting indicator lamp (option) 18 Power booster lamp...

  • Page 33: Description Of Instrument Panel

    Instruments and controls Description of instrument panel Description of instrument panel 1 Work lights lamp not applicable on EC330B) Control lamp (blue) S80845A 2 Battery charge warning lamp Control lamp (red) Included in the central warning system The lamp should be ON when the engine is running, indicating that S80483A the batteries are being charged.

  • Page 34: Engine Coolant Temperature Warning Lamp

    9 Automatic lubricating pilot lamp (option) Control lamp (red) The lamp is ON, if the grease tank is empty or the high pressure system is abnormal. (If needed, automatic lubricating system S80488A should be installed by Volvo dealers or distributors at local site)

  • Page 35: Coolant Level Lamp

    Instruments and controls Description of instrument panel 10 Coolant level lamp Control lamp (red) The lamp is ON if the coolant level becomes too low. If this hap- pens, check and add coolant. S80099A See Checking coolant level 11 Overload warning lamp (option) Control lamp (red) Included in the central warning system The lamp is ON and the buzzer sounds, if there is overload condi-...

  • Page 36: Power Booster Lamp

    Instruments and controls Description of instrument panel 15 Left/Right turn signal lamp Not applicable on EC330B) Control lamp (green) S80843A 16 Hammer selecting indicator pilot lamp (option) Control lamp (green) The lamp is ON, if the boost/hammer/shear selecting switch is set to hammer position.
  • Page 37 OFF when the start switch is turned to START( ) position. 25 Fuel heater lamp (not functional) Control lamp (green) S80489A 26 Emergency steering readiness lamp Not appli- cable on EC330B) Control lamp (green) S80965 27 Emergency steering operating lamp Not appli- cable on EC330B) Control lamp (amber)

  • Page 38: Description Of Instrument Panel

    Instruments and controls Description of instrument panel Right instrument panel 1 Engine speed control switch 2 Working lights switch 3 Power maximum mode selector switch 4 Auto idle selector 5 Travel speed selector switch 6 Boost/hammer/shear selector switch 7 Quickfit switch (option) 8 Quickfit audible warning switch (option) 9 Recirculation air sensor (option) 10 Upper wiper switch...

  • Page 39: Engine Speed Control Switch

    Instruments and controls Description of instrument panel 1 Engine speed control switch This switch is used to select the engine speed. Turning this switch, the engine speed will change incrementally. According to the selected engine speed, working mode will be set automatically and setting mode is displayed on the display unit, See Machine display unit on page 41.

  • Page 40: Working Lights Switch

    Instruments and controls Description of instrument panel 2 Working lights switch Position 0 Lights OFF Position 1 Instrument panel lamp and boom working lights ON. Position 2 Instrument panel lamp, boom working lights and deck work- ing lights ON. S82287 3 Power maximum mode selector switch Position 0 Power maximum mode DEACTIVATED...

  • Page 41: Boost/Hammer/Shear Selector Switch

    Instruments and controls Description of instrument panel 6 Boost / hammer / shear selector switch See 2 Operating lever (right) on page 54. If X1 (hammer / shear) is not equipped Position 0 Boost mode If button (C) on the right operating lever is pressed, digging S82290A power is increased for 9 seconds.
  • Page 42 Instruments and controls Description of instrument panel 7 Quickfit switch (option) IMPORTANT This function is activated by pressing the quickfit switch on the left and right instrument panels simultaneously, See Quickfit switch (option) on page 46. Switch (A) in position 0 Quickfit closed S82054D Switch (A) in position 1 Quickfit opend Switch (A) in position 2 Quickfit neutral...

  • Page 43: Lower Wiper Switch (Option)

    Instruments and controls Description of instrument panel 12 Lower wiper switch (option) Position 0 Wiper switched OFF Position 1 Wiper switched ON S80494A 13 Cigarette lighter Press it down, and in a few seconds it will return to the original po- sition.

  • Page 44: Flow Control Switch (Option)

    Instruments and controls Description of instrument panel 16 Flow control switch (option) This switch is used to set pump flow while optional equipment like a hammer or shear is operating (if equipped). Flow control Pump flow setting Flow control switch step lpm (gallon) current (±10 mA) 275 (73)

  • Page 45: Automatic / Manual Selector Switch

    Instruments and controls Description of instrument panel 19 Automatic / manual selector switch Position 1 Manual controlled Position 2 Auto controlled If the V-ECU malfunctions, this switch must be switched to Manual position. After changing damaged part, set this switch to automatic position. To turn manual mode to auto mode after changing or repairing damaged part, the machine must be restarted.
  • Page 46 Instruments and controls Description of instrument panel 20 Mute switch (option) This switch is used to mute the sound of one speaker at a time. Position 0 S82295 Position 1 21 Extra work lamp switch (option) Position 0 Extra work lamp (three lamps on Cab and one lamp on counterweight) switched OFF Position 1 Extra work lamp switched ON...
  • Page 47 Instruments and controls Description of instrument panel 24 Seat heating switch (option) This is used to warm for switching on and off the heating of the seat. Position 0 Seat heating OFF Position 1 Seat heating ON S82306 The seat heating functions when this switch is in position (1) and the temperature is under 11 °C ~ 17 °C (52 °F ~ 63 °F).
  • Page 48 Instruments and controls Description of instrument panel 27 Quickfit switch (option) IMPORTANT This function is activated by pressing the quickfit switch on the left and right instrument panels simultaneously, See Quickfit switch (option) on page 40. S82054E Switch (A) in position 0 Quickfit closed Switch (A) in position 1 Quickfit opend Switch (A) in position 2 Quickfit neutral When both switches are in position (1) simultaneously, the quickfit...
  • Page 49 Instruments and controls Description of instrument panel 31 Engine diesel heater (option) In cold weather, this auxiliary heater can be switched on manually or preset to activate at various times to warm the cab and heat the engine for easier starting. Time setting switch Memory indicator Program switch...
  • Page 50 Instruments and controls Description of instrument panel Presetting heating time starting The preset heating time can be selected for 3 different times every day or once a week. 1 Each preset time can be certified when program switch (B) is pressed.

  • Page 51: Display Unit

    Instruments and controls Display unit Display unit General The purpose of the display unit is to give the operator improved in- formation about the functions which are monitored by the E-ECU and V-ECU. In case of an error the display unit will show an error code.
  • Page 52 Instruments and controls Display unit 5 Main display window If the machine has an abnormal condition, an error code is dis- S82333 played in the window. If there are multiple error codes, they are displayed alternately and when pressing item selector switch (11), the error code is disap- peared.
  • Page 53 Instruments and controls Display unit 11 Item selecting switch When pressing this switch in series, figures on main display win- dow (5) change in series and the indicating lamp in question is ON. Engine rpm Engine speed indicating lamp (10) is ON S82319 Battery voltage Voltage indicating lamp (7) is ON.

  • Page 54: Diagnosis Content

    Instruments and controls Display unit Diagnosis content Contents Error code Group V-ECU ER11 E-ECU ER12 Controller & communication J1939 (fast link) ER13 J1587 (slow link) ER14 Electric Battery-Volt ER21 Power shift valve ER31 Hydraulic Flow control valve ER32 Engine oil temperature sensor ER41 Boost temperature sensor ER42...

  • Page 55: Controls

    Instruments and controls Controls Controls S82043 1 Operating lever (left) 4 Travel pedals 2 Operating lever (right) 5 Optional pedal (hammer / shear) 3 Travel levers 1 Operating lever (left) This lever is for swing and arm. Arm out Arm in Left swing Right swing S82045...
  • Page 56 Instruments and controls Controls Operating lever (right) This lever is for boom and bucket. Bucket in Bucket out Boom lower Boom raise S82046 Three button lever Left operating lever Right operating lever Rotator button Rotator button Horn button Unassigned S82255 Boost / hammer Horn button Thumb with three button lever...
  • Page 57 Instruments and controls Controls 3, 4 Travel levers and pedals WARNING! S82044 Keep your feet clear of the travel pedals when working. Know the track direction before operating travel pedals (levers). Travel operation will be reversed, when the sprocket is at the front.
  • Page 58 Instruments and controls Selecting valves for optional parts Selecting valves for optional parts 1 Bucket/clamshell valve position Select the correct position by turning the nut with a wrench. Bucket position Clamshell position S82170 2 Optional pedal position Position 1 Operating hammer (if equipped) Position 2 Operating Shear or Crusher (if equipped) Position 3...
  • Page 59 Instruments and controls Selecting valves for optional parts 3 Changing machine control pattern (option) Position S ISO type Position B Backhoe loader type Pattern change valve is equipped only on certain machines. WARNING! Whenever a change is made to the machine control pattern. Warning decal attached in air cleaner room should be carefully read before changing pattern change valve.

  • Page 60: Selecting Valves For Optional Parts

    Instruments and controls Selecting valves for optional parts Boom Lower (5): Move the control lever to this position in order to lower the boom. S83313 Bucket Dump (6): Move the control lever to this position in order to dump the bucket. S83314 Boom Raise (7): Move the control lever to this position in order to raise the boom.

  • Page 61: Operator Seat

    Instruments and controls Operator seat Operator seat Mechanical suspension seat WARNING! For one seated occupant. Do not adjust seat when an excavator is in operation. Keep clear of moving parts. Installation & maintenance should be carried out by authorized & competent personnel only. 1 Seat inclination adjustment 2 Weight adjustment 3 Backrest inclination adjustment...

  • Page 62: Safety Locking System

    Instruments and controls Safety locking system Safety locking system WARNING! Move the safety locking lever down to lock the system securely. Unless the safety locking lever is on the “Locked” (B) position, operating levers can be operated by careless touch, which could cause serious injury. Safety locking lever Unlocked position when this lever is put at this position the en- gine can not be started)
  • Page 63 Instruments and controls Cab window Cab window Move the safety locking lever down to lock the hydraulic system securely, See Safety locking system on page 60. before opening or closing the window. Opening the window 1 Lower the attachment to the ground and stop the engine. 2 Pull both latches (E) while holding both grips (F) and move up- ward in order to unlatch the window from lock (G).

  • Page 64: Door Lock System

    Instruments and controls Cab window Door lock system S82087A It is used to keep the operator’s cab door opened. 1 Push the door against outside of operator’s cab. 2 Ensure it is securely fixed to lock (A) Press lever (B) inside the operator’s cab to release the door. S82088 Roof window and rain visor WARNING!

  • Page 65: Glove Compartment

    Instruments and controls Cab window Glove compartment Glove Latch WARNING! Do not keep tools or a weighty thing in the glove. They can be dropped out of the glove by vibration of the machine or S82082 their weights when the equipment is operated, which may cause accidents, perhaps even fatal accidents.

  • Page 66: Cab Window

    Instruments and controls Cab window Ashtray Pull the top edge of the ashtray in order to open the ashtray. To remove the ashtray, pull the ashtray upword out of the console. NOTE : Make sure that you close the ashtray after use in order to pre- vent any possibility of a fire.

  • Page 67: Fire Extinguisher And Emergency Exit

    Instruments and controls Fire extinguisher and emergency exit Fire extinguisher and emergency exit Fire extinguisher (option) Mount fire extinguisher as follows. Remove two bolts (1) installed in the rear right side of cab interior and install the fire extinguisher. S81001 Emergency exit The emergency hammer (B) should be used in emergency sit- uations for:...

  • Page 68: Fuel Accessory Pump

    Instruments and controls Fuel accessory pump Fuel accessory pump WARNING! Stop the engine when fuelling. IMPORTANT Never let the fuel filler pump idle. The pump may be damaged. The pump is installed in the tool box. Use it when filling the fuel tank.

  • Page 69: Air Conditioner/Heater (Option)

    Instruments and controls Air conditioner/heater (option) Air conditioner/heater (option) The heating and air conditioning system is ON and ready for oper- ation when the electrical power is ON. This system operates when the automatic button is pressed. 1 Power switch Press this switch to stop operating this system.
  • Page 70 Instruments and controls Air conditioner/heater (option) 6 Compressor ON/OFF switch The cooling system operates only when fan speed control button (9) is ON. 7 Air flow selector button Ventilation is available in four modes. 8 Recirculation button S82056A To circulate inside air or to draw in outside air. When the lamp is ON, it is to circulate inside air.

  • Page 71: Radio And Cassette Player

    Instruments and controls Radio and cassette player Radio and cassette player S80534 1 Power/volume 2 Bass/treble 3 Balance 4 Seek/scan 5 Tune 6 Preset button 7 LCD for radio 8 Band selection button 9 Tape eject button 10 Cassette door 11 FF ( )/REW ( ) button...
  • Page 72 Instruments and controls Radio and cassette player...

  • Page 73: Operating Instructions

    Operating instructions Introduction Operating instructions Introduction This chapter contains operating and safety instructions that must be followed to ensure proper, safe machine handling/operation. However, these instructions do not relieve the operator from com- plying with national, provincial, state, municipal laws and regula- tions governing transportation safety, traffic safety, industrial safety and labour welfare.

  • Page 74: Running-In Instructions

    – The three oil filters should be replaced each time the oil is changed. – The oil filters should meet Volvo Construction Equipment spec- ifications, which is the case with genuine parts from Volvo Con- struction Equipment. – The sulphur content of the engine fuel must not exceed 0.3 per- cent by weight.

  • Page 75: Safety And Responsibility

    Operating instructions Safety and responsibility Safety and responsibility Operator duties The operator should know and pay attention to the specific require- ments and risks at his or her work site and discuss this with the rules stated below to learn how to avoid serious personal injuries and property damage.

  • Page 76: Working On A Slope

    Operating instructions Safety and responsibility Working on a slope WARNING! While travelling on a slope, keep the angle between boom and arm at 90 - 110 °, and raise the bucket 20 - 30 cm from the ground. S80032 Do not descend backward on a slope. Do not change direction or travel a cross on a slope.
  • Page 77 Operating instructions Safety and responsibility In case of shoes slipping If the shoes slip on a slope, thrust bucket into the ground, and pull the arm in to assist the track drive to move the machine up the slope. In case of engine failure In case of engine shut down while travelling on a slope, put the travel lever to neutral position and lower bucket down to the ground, then start the engine.

  • Page 78: Permissible Depth Of Water

    Operating instructions Safety and responsibility Never operate close to a high tension power line You can receive an electric shock if the machine approaches close to a high tension power line. Physical contact is not necessary to draw current from the power line! If working near a high tension power line, prohibit everyone from approaching the machine.

  • Page 79: Transporting The Machine

    Operating instructions Safety and responsibility Transporting the machine Loading and unloading WARNING! S80040A When transporting the machine, obey the relevant laws governing the weight, height, length and securing of a load. Choose a firm, level place, and keep ample distance from the road shoulder.
  • Page 80 Operating instructions Safety and responsibility Securing the machine 1 Move the safety bar down to lock the systems securely, See Safety locking system on page 60. 2 Stop the engine and remove the ignition key. 3 Turn OFF the battery master switch, See Mute switch (op- S82325C tion) on page 44.

  • Page 81: Caution For Optional Working Attachment

    Caution for optional working attachment Read this manual and the attachment manual before operating with attachments. Do not use any attachment not authorized by your Volvo dealer. Accidents or machine damage from unauthorized attachments shall be considered as user’s own responsibilities.

  • Page 82: Disassembling For Transportation

    Operating instructions Disassembling for transportation Disassembling for transportation NOTE : If any country (state) has its own regulation for machine weight limitation of transportation, disassemble the related parts for transportation. Complete dimensions. S83011 Parts to be disassembled for transportation. 3190 S83012 Rotating beacon lamp (option) When transportating the machine, dismantle rotating beacon lamp...
  • Page 83 Operating instructions Disassembling for transportation Disconnecting hydraulic hoses and lines WARNING! Immediately after operating the machine, the hot hydraulic oil can cause severe burns on unprotected skin. Hydraulic pressure can remain in the hydraulic system. Serious injury can result if this remaining pressure is not released before any service is done on the hydraulic system.
  • Page 84 Operating instructions Disassembling for transportation Disassembling components for transporta- tion IMPORTANT Follow the disconnecting hydraulic hoses and lines’ proce- dure before disassemble the components. Bucket and Arm with bucket cylinder Use cable sheaths (A) to protect the lifting cable from being dam- aged by the edges of the arm.

  • Page 85: Lifting Machine

    Use certified cables, slings, shackles and hooks of adequate load rating. Always lift the machine as shown below. Improper rigging can allow the load to shift and cause injury or damage. S82003E EC330B -40~60 -1.6~2.4 1050 45.9 41.3 27.9 Lift the machine on flat, firm and level ground.

  • Page 86: Counterweight Removal And Installation

    Operating instructions Counterweight removal and installation Counterweight removal and installation Standard machine WARNING! Move the safety locking lever down to lock the system securely, See Safety locking system on page 60. and attach a warning tag (do not start the engine) to the left operating lever.
  • Page 87 Operating instructions Counterweight removal and installation 8 Cover two covers and a plug from the top of counterweight. Tightening torque of bolts B: bolts: 90.2 ±9 kg·m C: bolts: 135 ±5 kg·m D: eye bolt specification: M48-P5...

  • Page 88: Changing Bucket

    Operating instructions Changing bucket Changing bucket Remove bucket WARNING! While striking the bucket pin with a hammer, metal chips may fly into your eyes. Always wear goggles, safety helmet and gloves while working. Support the removed bucket to stabilize it. S80250A 1 Lower the bucket lightly onto the ground.
  • Page 89 Operating instructions Hydraulic quickfit (s1) (option) Hydraulic quickfit (s1) (option) The quickfit consists of a flat plate assembly which is fitted to the arm end and bucket link. There are two hooks (F) on the plate, for the front pins (B) on the bucket. There is a lifting hook (C) on the quickfit.

  • Page 90: Removaing Bucket

    Operating instructions Hydraulic quickfit (s1) (option) Removaing bucket A: Red indicator pin B: Bucket pins C: Lifting hook D: Locking wedge E: Bucket rear hook F: Hooks for gripping attachment 1 Position the machine on even, firm and level ground with the bucket resting on the ground.

  • Page 91: Hydraulic Quickfit (S1) (Option)

    Operating instructions Hydraulic quickfit (s1) (option) Adjustment attachment A: Shims B: Bucket hook C: Locking wedge D: Screw holder E: Spacer F: Attachment bracket 1 Remove any shims between screw holder (D) and the mating plates. 2 Hook the bucket on and lock it in accordance with the instruc- tions for installing a bucket.

  • Page 92: Selecting Track Shoe

    Operating instructions Selecting track shoe Selecting track shoe Grouser Precautions when using Rocky ground, Travel in low speed when traveling on rough ground with obstacles normal soil such as large boulders and fallen trees. 600 mm Soft ground Travel in high speed only on flat ground. When it is impossible to avoid travelling over obstacles, lower the travel speed to approxi- mately half of low speed.

  • Page 93: Hose Rupture Valves (Option)

    Contact an authorized Volvo CE dealer workshop, if problems occur. Hydraulic oil is hot, poisonous and under high pressure.
  • Page 94 Operating instructions Before operating Before operating General rules WARNING! Breaking these rules may lead to an accident, serious injures or death. – Read and understand: – This Operator’s Manual before you begin to operate the machine S80644 – Plates and instructions which are attached to the machine before you begin to operate or service the machine.

  • Page 95: Before Operating

    Operating instructions Before operating Procedures before starting IMPORTANT Always walk around the machine before starting and check that there are no persons in the immediate vicinity of the machine. 1 Place the machine in the service position. See Service posi- tion on page 120.

  • Page 96: Stop Position

    Operating instructions Start switch Start switch The start switch (A) has three position. S82108A Stop position The engine stops immediately. S82301 Running (preheating) position When the switch is in this position: – The electronics is started up – The electronics is up and running –...

  • Page 97: Start Switch

    Operating instructions Start switch Checking instruments, warning and control lamps Turn the switch to running ( ) position, then the following control lamps should light up: The lamps are ON for three seconds and the buzzer sounds twice. Battery charge warning and engine oil pressure warning lamps still light up before starting.

  • Page 98: Starting Engine

    Operating instructions Starting engine Starting engine See Safety locking system on page 60. WARNING! After checking for personnel and obstructions around the machine, start the engine and sound the horn. Do not operate the operating levers and switches when starting. IMPORTANT S80510A Do not hold the key at the STARTING (...

  • Page 99: Procedures In Cold Weather

    Operating instructions Starting engine Procedures in cold weather During the cold season or at temperatures below 0°C (+32°F), note the following points: – Make sure that the freezing point of the coolant corresponds to the weather conditions. See Coolant with antifreeze and cor- rosion protection on page 145.
  • Page 100 Operating instructions Operating machine Operating machine Operating attachment WARNING! While auto idling, if an operating lever is operated, the engine speed returns to its original speed. Left operating lever This lever controls swing and arm. Neutral (upper frame and arm are maintained at rest position.) Arm out Arm out and right swing Right swing...

  • Page 101: Travel Direction Control

    Operating instructions Operating machine Travel direction control WARNING! Check the track direction before operating travel levers or pedals. If the sprocket is at the front of the machine, travel levers (pedals) must be operated in the opposite direction. Do not change the travel direction rapidly. Especially, in case of stationary direction change, stop the machine.

  • Page 102: Operating Machine

    Operating instructions Operating machine Left turning When the sprocket is at the rear of the machine: Push right lever (D) forward, the R/H track rotates forward and the machine travels forward as it turns to the left. Pull left lever (C) backward, the L/H track rotates in reverse and the machine travels backward as it turns to the left.

  • Page 103: After Operating

    Operating instructions After operating After operating WARNING! When you are entering and leaving the machine, always face the machine and use the steps or hand holds to avoid slipping. Always use the three-point stance, i.e. two hands and one foot or two feet and one hand when climbing up onto or descending from the machine.

  • Page 104: Parking

    Operating instructions Parking Parking General IMPORTANT Select level ground to park the machine. If it is unavoidable to park on a slope, put a wood block under each track and thrust the bucket teeth into the ground. – Pay attention to the weather and take the appropriate steps so that the machine does not freeze to the ground, sink or suffer any other consequences.

  • Page 105: Towing Method

    Operating instructions Towing method Towing method WARNING! Use a wire rope of sufficient strength for the towing. S83019 Towing for heavy objects In the event of slipping into swampy ground or towing heavy ob- jects, attach a wire rope to tow the machine as shown in the illus- tration.

  • Page 106: Anti-Vandalism (Option)

    Operating instructions Anti-vandalism (option) Anti-vandalism (option) Anti-vandal covers are stored in two places, on the cab and by the tool box. Four covers stored by the tool box are installed at front windows (A) and door windows (B) Three covers stored on the cab are installed at right side window (C) and rear window (D).

  • Page 107: Loading Work

    Operating instructions Work with bucket Work with bucket The excavator is a multi-task machine capable of being fitted with a multitude of special attachments to perform many types of work. Only the simplest operations are described below. Backhoe work For digging work at a lower level than the machine is located. When the angle between bucket cylinder and links, arm cylinder and arm is set to 90 °...

  • Page 108: Float Position (Option)

    Operating instructions Work with bucket Float position (option) WARNING! S83062 Always make sure that the boom operating lever is in the neutral position before activating the float position. Do not select the float position mode while the track or tracks are elevated: Selecting the float position mode and operating the boom operating lever forward (boom down position) while the track or tracks are elevated could cause the machine to...

  • Page 109: Work With Bucket

    Operating instructions Work with bucket When working, do not Do not strain the slewing mechanism Do not use the slewing force for raking over the ground, demolition of buildings or thrusting bucket teeth into the ground. This opera- tion may cause damage to the machine and attachments. S82144 Do not work with the travelling motors Do not dig by using the travelling motors, and thrusting bucket...
  • Page 110 If permitted a properly installed rated bucked hook and certified slings / shackles is required. Contact an authorized Volvo CE dealer workshop. S82154 Working by drop force of the machine body Do not operate by dropping the machine body.

  • Page 111: Escaping From Swampy Ground

    Operating instructions Escaping from swampy ground Escaping from swampy ground Be very careful when working on swampy ground. In case that one track gets bogged If one track gets bogged down, raise this track using the bucket and put a plank under the track. IMPORTANT When raising the machine using boom or arm, use the bottom of the bucket.
  • Page 112 Operating instructions Signalling diagram Signalling diagram For manual signalling to operator of a mobile excavator as per SAE J1307. The primary use of hand signals is for a signalman to direct the lift- ing, handling and placement of loads attached to working equip- ment.
  • Page 113 Operating instructions Signalling diagram Lower boom With either arm extended horizontally, fingers closed, point thumb downward. S81466 Swing With either arm extended horizontally, point with forefinger to di- rection of swing rotation. S81467 S81468 Dipper arm inward With both hands clenched, point thumbs inward. S81469 Dipper arm outward With both hands clenched, point thumbs outward.
  • Page 114 Operating instructions Signalling diagram Open bucket Hold one hand open and stationary. Rotate other hand in small ver- tical circle with forefinger pointing horizontally at open hand. S81472 Turn Raise forearm with closed fist indicating inside of turn. Move other fist in vertical circle indicating direction of track or wheel rotation.

  • Page 115: Signalling Diagram

    Operating instructions Signalling diagram This far to go With hands raised and open inward, move hands laterally, indicat- ing distance to go. S81479 Move slowly Place one hand motionless in front of hand giving motion signal. Raise load slowly is shown. S81480 Stop With either arm extended laterally, hand open downward, move...

  • Page 116: Lifting Objects

    NOTE : Use of a safety lift hook not recommended by Volvo CE could result in structural damage to the machine. Consult your Volvo CE dealer regarding the installation of a local bucket.

  • Page 117: Optional Parts

    Select the proper attachment in accordance with the machine on which the attachment is installed. The type of attachment which is able to be installed varies with the machine type. Contact an authorized Volvo dealer workshop. Hydraulic hammer Main works –...
  • Page 118 Operating instructions Optional parts The striking direction of chisel and the direction of breaker body are deviate slightly. Therefore, adjust the bucket cylinder so that the direction of body and chisel is always the same. S82172 Press the chisel firmly against the surface so idle striking is avoid- S80359 Caution during hammer operation Do not operate the cylinder to its end of stroke, leave about 5 cm.
  • Page 119 Operating instructions Optional parts Do not move the chisel while it is striking a blow. S82174 Do not strike horizontally, or in an upward direction. S82175 Do not bend with the chisel to make a hole in the ground. S82176 Do not hoe the chisel.
  • Page 120 Operating instructions Optional parts...

  • Page 121: Safety When Servicing

    – grasp hold of hoses instead of handholds – uses the wrong tool for the job. In order to maintain safe and efficient function, always use Volvo Construction Equipment genuine spare parts. Machines rarely cause accidents, whereas incorrect handling of- ten does.

  • Page 122: Service Position

    Safety when servicing Service position Service position WARNING! If you have to work on a machine before it has cooled down, beware of hot fluids and components which can cause burns. Before you begin any service work, the machine should be placed on level ground and prepared for service as shown below: S82192 1 Position the machine on even, firm and level ground.

  • Page 123: General

    Safety when servicing General General WARNING! Breaking these rules may lead to an accident, serious injuries or death. – Read all plates and decals on the machine and in the Opera- tor’s Manual before carrying out service on the machine. Each of the instructions contain important information about the han- dling and service of the machine.
  • Page 124 – All lifting devices, e.g. straps, slings, ratchet blocks etc. must comply with national regulations for lifting devices. Volvo Con- struction Equipment will not accept any responsibility if any lift- S80646A ing devices, tools or working methods are used other than those described in this publication.

  • Page 125: Handling Lines, Tubes And Hoses

    Do not install any lines that are bent or damaged. Check lines, tubes and hoses carefully. Leaks may cause fires. Consult your Volvo CE dealer for the repair or for replacement parts. Do not use your bare hand to check for leaks.
  • Page 126 Safety when servicing Measures to prevent fire Measures to prevent fire WARNING! If the machine is used in an environment where the risk of fire is particularly high, e.g. in explosive environment, special equipment is required. NOTE : If a high-pressure jet machine is used for cleaning, take great care as the electrical components and electrical leads can become damaged even at fairly low water pressure and temperature.
  • Page 127 Safety when servicing Measures to prevent fire – Keep the work-place where the service is to be carried out clean. cleanliness is of decisive importance for trouble-free op- eration of systems in the machine. Oil or water make floor and steps slippery and also dangerous in connection with electrical equipment or electrically powered tools.

  • Page 128: Measures To Prevent Fire

    Safety when servicing Measures to prevent fire Risks in connection with polymer materials Working on painted surfaces WARNING! All paint decomposes when heated and forms a great number of compounds. These substances may be irritating and after long or frequent exposure may constitute a serious health hazard.
  • Page 129 Safety when servicing Measures to prevent fire Fluor rubber WARNING! Certain seals which are designed to withstand high operating temperatures (e.g. engines, main control valve hydraulic motors and pumps) may be made from fluor rubber. When heated to high temperatures, fluor rubber decomposes to hydrogen fluoride and hydrofluoric acid, which is strongly corrosive.
  • Page 130 Safety when servicing Batteries Batteries Rules for batteries IMPORTANT Batteries contain substances which are harmful to health and the environment. Scrapped batteries must therefore be taken care of in accordance with relevant local/national regu- lations. – Batteries give off explosive gases. Never smoke around any batteries.

  • Page 131: Batteries

    Safety when servicing Batteries Starting with booster cable WARNING! Because of current surge the batteries may explode if a fully charged battery is connected to a discharged battery. Such an explosion can cause injuries. When starting with booster batteries check that the booster batter- ies or other power source has the same voltage as the standard batteries.
  • Page 132 Safety when servicing Air conditioning Air conditioning Refrigerant General Refrigerant R134a is used in the air conditioning units. When R134a is used, there is also a type plate near the receiver drier. R134a has no potentially depletion properties that will affect the ozone layer of the atmosphere, but R134a adds to the green house effect and must never intentionally be released into the open air.

  • Page 133: Air Conditioning

    Never disconnect hoses and never remove the filler plug on the compressor. If a leak is suspected, do not try to refill the system. Contact an authorized Volvo dealer workshop for them to take action. – When carrying out work with emptying (discharging) or refilling (charging) refrigerant, equipment specially intended for this work must be used.

  • Page 134: Use Handholds And Steps For Climbing On / Off

    Safety when servicing Use handholds and steps for climbing on / off Use handholds and steps for climbing on / off S82193 WARNING! Always observe this caution for safety. Don’t jump on/off a machine. Especially, never get on / off a mov- ing machine.

  • Page 135: Service And Maintenance

    – The three oil filters should be replaced each time the oil is changed. – The oil filters meet the Volvo Construction Equipment specifica- tions, which is the case with genuine parts from Volvo Con- struction Equipment. – The sulphur content of the engine fuel must not exceed 0.3 per- cent by weight.
  • Page 136 Service and maintenance Engine Changing oil 1 Place the machine in the service position. 2 Put a container (above 50 liter) under the protecting cap (E) at the bottom of the engine oil pan. 3 Remove protecting cap (E) and attach drain hose (F) provided as a service tool with machine.

  • Page 137: Replacing Engine Oil Filter

    This is to ensure lubrication immediately after starting. WARNING! Take care of waste oil/liquids in an environmentally safe way! Valve clearance Valve clearance, adjusting Check the valve clearance every 2000 hours. The work should be carried out by an authorized Volvo dealer workshop.

  • Page 138: Fuel Tank

    Service and maintenance Fuel system Fuel system Fuel tank Clean fuel is essential for trouble-free running of the diesel engine. The fuel tank holds 565 liters (149.3 US gal). Carefully clean around the filler cap before removing it. Avoid spill- ing fuel when filling as this attracts dirt.

  • Page 139: Fuel System

    Service and maintenance Fuel system Draining water from water separator Check the water daily. Drain the water, put a vessel under drain hose (F). The water separator is designed to remove water from the fuel supply to the engine. When water is visible over drain level (D), open drain valve (E) to drain water.

  • Page 140: Bleeding Fuel System Of Air

    Service and maintenance Fuel system Bleeding fuel system of air WARNING! Make sure that fuel under high pressure cannot come into contact with unprotected parts of your body when working with fuel injection equipment. If the tank has been run dry or if air has got into the system for oth- er reasons, the system must be bled for air.

  • Page 141: Intercooler

    Service and maintenance Intercooler Intercooler The engine is provided with an air-to air type intercooler. The inter- cooler lowers the temperature of the induction air by approximately 100°C (212°F). The induction air then becomes more dense, so that more fuel can be injected and combusted. This will result in a higher engine output, but the colder air also leads to less stress on valves and pistons.
  • Page 142 Service and maintenance Air cleaner Air cleaner General The air cleaner prevents dust and other impurities from entering the engine. The air first passes through the primary filter and then the secondary filter. The degree of engine wear depends largely on the cleanliness of the induction air.

  • Page 143: Air Cleaner

    Service and maintenance Air cleaner Cleaning primary filter Mechanical cleaning 1 Carefully tap the end of the primary filter against a soft and clean surface. NOTE : Do not tap against a hard object. Cleaning with compressed air 1 Use clean and dry compressed air with a max. pressure of 500 kPa (5 bar) (73 psi).

  • Page 144: Oil Bath Air Cleaner (Option)

    Service and maintenance Oil bath Air cleaner (option) Oil bath Air cleaner (option) Checking screen filter service Check the outside, inside oil (9.4Liters) cup daily. The removable and fixed filters are the most sensitive operational parts of the air cleaner. Unless they are kept clean, the air cleaner cannot function properly.

  • Page 145: Oil Bath Air Cleaner (Option)

    Service and maintenance Oil bath Air cleaner (option) 4 Dry thoroughly with compressed air S82273 5 Inspect body – Each time the oil cup is serviced, inspect lower portion of body assembly and center tube for structural integrity. Replace bro- S82274 ken, cracked, or missing parts.
  • Page 146 Service and maintenance Cooling system Cooling system General If the engine temperature becomes too high even though the cool- ant level is correct, the radiator should be cleaned. IMPORTANT Take care so as not to damage the fins on the radiator core. If the engine temperature still remains high, contact an authorized dealer workshop for remedial action.

  • Page 147: Cooling System

    Check the antifreeze properties every 500 hours. When delivered from the factory, the cooling system is filled with a mixture of water and concentrated Volvo Construction Equipment antifreeze, which lowers the freezing point and raises the boiling point of the coolant.

  • Page 148: Changing Coolant

    Service and maintenance Cooling system Changing coolant Change the coolant every 2000 hours. Draining coolant 1 Remove the radiator bottom cover and put a container under drain cock (B). 2 Loosen radiator cap (A) 3 Open cock (B). NOTE : The cooling system does not become safe against frost even after draining.

  • Page 149: Changing Coolant Filter

    If the engine is started with the engine hood open, no person is al- lowed at the front end of the machine. The filter should be replaced every 1000 hours, provided Volvo Construction Equipment original anti-freeze is used. To gain access to the filter, let down the belly plate. Filter (A) is po- sitioned down to the right on the engine.

  • Page 150: Master Switch

    Service and maintenance Electrical system Electrical system Master switch IMPORTANT The machine is provided with an alternator. The battery master switch must therefore always remain turned ON while the engine is running. If it is turned OFF, or if the start switch is turned OFF while the engine is running, the alternator may be damaged.

  • Page 151: Electrical System

    Service and maintenance Electrical system Rules for batteries See Batteries on page 128. Charging batteries See Charging batteries on page 129. Alternator Alternator belt tension Check the belt tension daily. WARNING! The engine must be stationary when checking the belt tension, rotating parts can cause injuries.

  • Page 152: Battery Connection

    Service and maintenance Electrical system Battery connection – The battery terminals must never be confused. Each terminal is clearly marked with a (+) or a (-) sign respectively. If the cables are wrongly connected, the alternator rectifier will be ruined im- mediately.

  • Page 153: Electrical Distribution Box

    Service and maintenance Electrical system Electrical distribution box General The machine has an electrical distribution box (A) installed to the right of the operator seat. The electrical distribution box contains most of the fuses and relays of the machine. WARNING! Never install a fuse with a higher ampere rating than that stated on the decal (risk of damage or fire on the circuit board).
  • Page 154 Service and maintenance Electrical system Fuse capacity and symbol related circuits S82029 Capacity Appliance / circuit Capacity Appliance / circuit Instrument panel Start switch Working lights (deck) Cab light Working lights (boom) Radio and cassette Wiper & washer Auxiliary heater Power outlet Cigarette lighter Fuel filler pump...

  • Page 155: Hydraulic System

    Service and maintenance Hydraulic system Hydraulic system IMPORTANT Exercise cleanliness when filling oil and in all work on the hydraulic system. Checking hydraulic oil level Check the oil level daily 1 Retract the bucket cylinder completely, retract the arm cylinder completely and lower the boom to the ground.

  • Page 156: Changing Hydraulic Oil

    Service and maintenance Hydraulic system Changing hydraulic oil Change the hydraulic oil every 2000 hours WARNING! Take care when changing oil. Hot oil can cause burns on unprotected skin. 1 Swing the superstructure so that drain plug (F) at the bottom of the hydraulic tank is located between the left and right tracks.

  • Page 157: Replacing Hydraulic Oil Return Filter

    Service and maintenance Hydraulic system Replacing hydraulic oil return filter Replace the return filter after the first 250 hours and then ev- ery 1000 hours. WARNING! Before removing cover (A), release the internal pressure of the tank. 1 Unscrew cover (A) 2 Remove O-ring (B), spring (C) and bypass valve (D), and then pull out filter.

  • Page 158: Replacing Element In The Pilot Filter

    Service and maintenance Hydraulic system Replacing element in the pilot filter Replacing the element in the pilot filter after the first 250 hours and then every 1000 hours. 1 Place a container under the filter 2 Remove the filter bowl 3 Replace the inner element of the pilot filter.
  • Page 159 Service and maintenance Hydraulic system Replacing element in the return filter for hammer circuit (option) Replace the element in the return filter for hammer circuit ev- ery 200 hours. (on the basis of hammer working hours) 1 Stop the engine. 2 Loosen drain plug (D) to drain hydraulic oil from case (B).

  • Page 160: Swing Drive Unit

    Service and maintenance Swing drive unit Swing drive unit General IMPORTANT Always clean around the oil level gauge before you check the oil level. Dirt in the oil damages the swing drive case. It is very important that the oil level is always correct and that it is checked at working temperature.

  • Page 161: Track Drive Unit

    Service and maintenance Track drive unit Track drive unit General IMPORTANT Always clean around the check plug before you check the oil level. Dirt in the oil damages the track drive case. It is very important that the oil level is always correct and that it is checked at working temperature.

  • Page 162: Handling Accumulator

    Do not hit, drill, or weld the accumulator. Keep it away from open flame or other high heat sources. Ask your authorized Volvo CE dealer workshop to discharge the pressure in the accumulator prior to disposal.
  • Page 163 Service and maintenance Swing gear and bath, greasing Swing gear and bath, greasing Greasing swing gear bearing Grease the swing gear every 250 hours.Park the machine on a level surface. 1 Park the machine on level ground. 2 Lower the bucket to the ground. 3 Turn the ignition key to STOP ( ) position.
  • Page 164 Service and maintenance Swing gear and bath, greasing Greasing excavator unit Grease a new machine every 10 hours or daily only during the first 100 hours. After the first 100 hours of operation, grease the excavator unit every 50 hours or weekly. NOTE : Under severe operating conditions where mud, water, and abrasive material may enter the bearings, or after using the hydraulic hammer, the excavator unit should be greased every 10 hours or daily.
  • Page 165 Service and maintenance Swing gear and bath, greasing Refilling grease to attachment Service the new machine Every 10 Service Hours or Daily only within the initial 100 service hours. After the initial 100 service hours of operation, service the attachment linkage Every 50 Service Hours or Weekly.

  • Page 166: Swing Gear And Bath, Greasing

    Service and maintenance Swing gear and bath, greasing Recommended grease Product name Region Manufacturer General region The tropics ESSO ESSO EP2 BEACON Q2 CALTEX MULTIFAX EP2 MARFAK ALL PURPOSE 2 GULF GULF CROWN EP2 GULFCROWN EP2 (SPECIAL) MOBIL MOBILUX EP2 MOBILUX EP2 (SPECIAL) SHELL ALVANIA EP2...

  • Page 167: Air Conditioner

    The system contains HFC (R134a) under pressure. By law, HFC must not be deliberately released. Repairs and re-filling of the refrigerant system must only be done by trained personnel. Contact your authorized Volvo Construction Equipment workshop. Change air conditioner/heater filter every 1000 hours or...
  • Page 168 Service and maintenance Track slack Track slack Inspecting and adjusting the track slack Check the slack every 100 hours. WARNING! When two persons are working, the operator should follow the sign of the maintenance worker. For inspecting the track tension, the track must be lifted off the ground.

  • Page 169: Track Slack

    If the tension can not be adjusted by the way shown in this manual, contact an authorized Volvo CE dealer workshop. Tightening track tension - reducing slack 1 Fill the grease through grease nipple (B) using a high pressure grease gun.

  • Page 170: Tightening Track Shoe Bolts

    Service and maintenance Track slack Tightening track shoe bolts Check the shoe bolts daily. If track shoe bolts (1) are loose, the track shoes are likely to be damaged. Therefore check for looseness and tighten the bolts to specified torque, 105 ~ 115 kgf·m. Retightening After tightening with a torque of 105 ~ 115 kgf·m, check whether the nut and the shoe are in full contact with the mating surfaces of...

  • Page 171: Replacing Bucket Teeth

    Service and maintenance Replacing bucket teeth Replacing bucket teeth Replace the bucket teeth before the adaptors wear away. WARNING! When changing the bucket teeth, always: Lower the bucket to the ground, position to the easiest posture for working, stop the engine. Place a block (A) under the bucket, then lower the bucket keeping it horizontal.

  • Page 172: Heavy Excavating (Vertical Pin), Esco

    Service and maintenance Replacing bucket teeth Heavy excavating (vertical pin), ESCO 1 Drive out locking pin (B) using a hammer and punch. Turn tooth (A) counter-clockwise and pull it off. 2 Thoroughly clean adapter (C), remove all mud and rust. Push a new tooth (A) onto adapter (C) and turn it clockwise un- til the tooth is properly seated, ensuring that the retaining pin hole and groove are aligned.

  • Page 173: Lubrication

    Service and maintenance Lubrication Lubrication General Lubrication is an important part of preventive maintenance. The service life of bushings, bearings and bearing pins can be extended considerably if the machine is lubricated in a cor- rect way. A Lubrication chart makes Lubrication work easier and reduces the risk of forgetting greasing points.
  • Page 174 Service and maintenance Lubrication and service chart Lubrication and service chart 10 (daily), 50, 250, 500, 1000, 2000 and 3000 hour services 3000h 2000h 1000h 500h 250h 250h 500h 1000h 2000h 3000h S82246...

  • Page 175: Checks, Oil Changes And Lubrication

    Service and maintenance Lubrication and service chart Checks, oil changes and lubrication Measure page Daily = every 10 hours Check: Engine oil level FGA Air cleaner outside, inside separator Coolant level Draining water from water separator Battery electrolyte level Alternator belt tension Hydraulic oil level Tightening of track shoe bolts Measure...

  • Page 176: Lubrication And Service Chart

    Service and maintenance Lubrication and service chart Measure page Every 250 hours After you have carried out Daily and 100 hour services: Check: Water pump, belt tension Oil level of swing drive case Oil level of track drive case Lubricate: Refilling grease to swing gear bearing Measure page...
  • Page 177 Service and maintenance Lubrication and service chart Measure page Every 1000 hours After you have carried out Daily, 100, 250 and 500 hour services: Clean: Strainer (hydraulic tank) Change: Coolant filter Fuel filter Water separator element Hydraulic element of pilot filter (First change after 250 hours) Oil of swing drive case (First change after 500 hours)

  • Page 178: Periodic Replacement Of Safety Critical Parts

    When replacing the hoses, always replace the O-rings, gaskets, and other such parts at the same time. Ask your Volvo CE dealer to replace the safety critical parts. Inspection interval...

  • Page 179: Specifications

    Specifications Recommended lubricants Specifications Recommended lubricants Ambient temperatures Specification Kind of Capacity l (gal) Reservoir fluid 104 122°F Total amount 40 50°C SAE 10W SAE 10W–30 Engine oil ∗ SAE 15W–40 Engine oil 46.5 (12.2) SAE 30 SAE 40 ISO VG 32 ∗∗...
  • Page 180 If sulphur content > 0.5 % then 125 hours drain interval must be practiced. Maximum 6 months between oil change. If the oil grade is lower than ACEA-E3 or API CE, 125 hours drain interval must be practiced. Only genuine Volvo CE coolant should be used.

  • Page 181: Capacities, Lntervals Between Changes

    Specifications Capacities, lntervals between changes Capacities, lntervals between changes Capacities Total Liters US gal Engine oil including Filter 46.4 12.2 Cooling system 65.4 17.2 Hydraulic tank 58.1 Swing gearbox (each) 1.59 Track gearbox (each) 1.45 Fuel tank 163.8 Swing ring gear Oil bath air cleaner oil 2.48 Intervals between changes...

  • Page 182: Specifications

    Specifications Specifications Specifications Engine Maker Volvo D12CECE2 Type 4–stroke, 6–cylinder, straight, water cooled, direct injection, diesel engine, turbocharger, after cooled Rated output 250 PS/ 1700 rpm Maximum torque (Net) 138 kgf·m/ 1275 rpm Bore ×Stroke 120.65 mm × 140 mm 12.13 l...

  • Page 183: Control Levers

    Specifications Specifications Main control valve Model KMX32N Main relief pressure 320/ 350 kgf/cm (STD/ Boost pressure) 4550/ 4980 psi (STD/ Boost pressure) Port relief pressure 365 kgf/cm (5190 psi) (Boom/ Arm/ Bucket) 150/ 365 (Option STD/ High) Track motor and reduction gear Track motor Model KDB172 - 172/125B...

  • Page 184: Sound And Vibration Levels

    Specifications Sound and vibration levels Sound and vibration levels Noise level in operator’s cab Sound pressure level (LpA) Enclosed Cab, (see decal value inside the cab) The sound is measured according to ISO 6396 and 98/37/EC, in- cluding applicable amendments. Sound power level (LwA) around the machine (see decal value in- side the cab) The sound is measured according to ISO 6395 and 2000/14/EC,...

  • Page 185: Dimensions

    Specifications Dimensions Dimensions S82247 6.2 m Boom 6.45 m Boom Unit 20' 4" 21' 2" Description 2.6 m Arm 2.6 m Arm 3.2 m Arm 3.9 m Arm 8' 6" 10'6" 12' 10" 8' 6" 2990 2990 2990 2990 A. Overall width of superstructure ft-in 9’10”...

  • Page 186: Bucket & Arm Combination

    Specifications Bucket & Arm combination Bucket & Arm combination Volvo bucket and LC undercarriage Description Direct fit -GP bucket Quick fit -GP bucket Bucket capacity: SAE 1380 l 1450 l 1380 l 1450 l 1.81yd 1.90 yd 1.81 yd 1.90 yd...
  • Page 187 Specifications Bucket & Arm combination Maximum permitted buckets for direct fit Undercarriage 6.2 m Boom 6.45 m Boom Monobloc Boom Unit 20’4” 21’2” 2.6 m Arm 2.6 m Arm 3.2 m Arm 3.9 m Arm Dipper Arm 8'6" 8'6" 10' 6" 12' 10"...
  • Page 188 Specifications Bucket & Arm combination Maximum permitted buckets for direct fit Undercarriage 6.2 m Boom 6.45 m Boom Monobloc Boom Unit 20’4” 21’2” 2.6 m Arm 2.6 m Arm 3.2 m Arm 3.9 m Arm Dipper Arm 8'6" 8'6" 10' 6" 12' 10"...
  • Page 189 Specifications Bucket & Arm combination Boom & Arm Boom 6.2 m 6.45 m Description 20' 4" 21' 2" 6460 6700 Length 21' 2" 21' 12" 1740 1800 Height ft-in 5' 9" 5' 11" Width 2' 8" 2' 8" 3230 3010 Weight * 7120 6640...

  • Page 190: Digging Force With Direct Fit Bucket

    Specifications Digging force with direct fit bucket Digging force with direct fit bucket 6.2 m Boom 6.45 m Boom 21’4” 22’12” Description Unit 2.6m Arm 2.6m Arm 3.2m Arm 3.9m Arm 8’6” 8’6” 10’6” 12’10” 1810 1623 1623 1623 Bucket radius 71”...

  • Page 191: Working Ranges

    Specifications Working ranges Working ranges Direct fit bucket S82248 6.2 m Boom 6.45 m Boom 20' 4" 21' 2" Description Unit 2.6 m Arm 2.6 m Arm 3.2 m Arm 3.9 m Arm 8'6" 8'6" 10' 6" 12' 10" 10480 10540 11060 11700...

  • Page 192: Care And Maintenance Journal

    Specifications Care and maintenance journal Care and maintenance journal Date Hours Signature Notes...
  • Page 193 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 194 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 195 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 196 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 197 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 198 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 199 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 200 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 201 Specifications Care and maintenance journal Date Hours Signature Notes...
  • Page 202 Specifications Care and maintenance journal Date Hours Signature Notes...

  • Page 203: Alphabetical Index

    Alphabetical index Alphabetical index Communication equipment, installation....3 Contents ..............5 Accumulator releasing pressure......160 Controls ..............53 Adjusting air conditioner belt tension ....165 Coolant............... 145 Adjustment attachment .........89 Cooling system........... 144 After operating.............101 Counter-rotation ..........100 Air cleaner ............140 Counterweight installation ........84 Air conditioner .............165 Counterweight removal and installation ....
  • Page 204 Alphabetical index General ..............72 Operating machine..........98 Operation of accumulator (in emergency) ..160 General ..............91 Glove compartment..........63 Operator duties ............ 73 Greasing excavator unit ........162 Operator manual storage ........64 Greasing swing gear bearing ......161 Operator qualifications ......... 73 Guidelines ...............3 Operator seat ............
  • Page 205 Transporting the machine ........77 Travel direction control..........99 Turbocharger............139 Use handholds and steps for climbing on / off ..132 Valve clearance...........135 Volvo bucket and LC undercarriage....184 Volvo bucket and LC undercarriage....184 Warranty inspection ..........24 Water pump, belt tension ........147 When starting ............93 When working, do not .........107...
  • Page 206 Ref. No. : VOE 2134355130 English Printed in Sweden...

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