Volvo EC60E Operator'S Manual Download Page 249

Page: 249 / 342

applicable form, which must be signed, if the

warranty is to apply.

Service Programme

For any factory warranty to be valid, the machine

shall be maintained according to the service

program established by Volvo. The service program

is continuous with fixed intervals. The operating

time between intervals only applies if the machine

is used in normal environment and operating

conditions. Ask your Volvo dealer what is right for

your specific machine.

248

Maintenance

Summary of Contents for EC60E

Page 1: ...VOLVO CONSTRUCTION EQUIPMENT ec60E operator s manual ...

Page 2: ...invested in achieving the best possible efficiency and safety But accidents do happen and most of them can be attributed to human error A safety conscious person and a well maintained machine make up a reliable powerful and profitable combination Therefore read the safety instructions and follow them We constantly strive to develop and improve the efficiency of our products by making changes to th...

Page 3: ...erious injury Danger is limited to the most extreme situations WARNING The safety symbol combined with this signal word indicates a hazardous situation which if not avoided could result in death or serious injury CAUTION The safety symbol combined with this signal word indicates a hazardous situation which if not avoided could result in moderate or minor injury NOTICE Indicates a potentially hazar...

Page 4: ...arts Manufacturer Volvo Group Korea Co Ltd Seongsan gu Changwon si Gyeongsangnam do Korea 51710 Machine PIN Serial number Engine Main pump Swing motor Track motor Main control valve Please send any comments about the Operator s Manual to om volvo com Open source code used in this product can be got from the following web site http webdoc volvo co kr exc oss Foreword Identification numbers 3 ...

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Page 6: ...t 35 Instrument panel front 38 Display unit 45 Instrument panel right 86 Instrument panel rear 98 Other controls 99 Controls 100 Cab 112 Control lockout system 114 Operator comfort 115 Operating instructions 136 Safety rules when operating 142 Measures before operating 147 Starting engine 148 Hydraulic system warming up 152 Operating 154 Exhaust aftertreatment system 155 Stopping 162 Parking 163 R...

Page 7: ...6 Safety when servicing 229 Service position 230 Before service read 231 Entering leaving and climbing the machine 237 Fire prevention 238 Handling hazardous materials 241 Handling line tubes and hoses 246 Maintenance 247 Lubrication and service chart 249 Maintenance service every 10 hours 258 Maintenance service every 50 hours 265 Maintenance service every 250 hours 267 Maintenance service every ...

Page 8: ...ange intervals 309 Engine 311 Electrical system 312 Cab 314 Hydraulic system 315 Machine weights 317 Ground pressure 318 Dimensions 320 Working ranges 322 Recommended bucket sizes 324 Digging forces 325 Lifting capacities 326 Service history 334 Alphabetical index 337 Table of contents 7 ...

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Page 10: ... flammable environment or areas with dust containing asbestos and so on special safety regulations must be followed and the machine be equipped for such use Contact the manufacturer dealer for further information Environmental requirements Be aware of the environment when operating and during service and maintenance of the machine Always follow local and national environmental legislation applicab...

Page 11: ...of the latest EU Stage IV US Tier 4 final emissions regulations NOTE Machines with engines for the US market may not be sold or used within the EU and machines with engines for the EU market may not be sold or used within the USA unless the engine is replaced with an engine valid for the applicable market The market for which the engine is intended is indicated on the emission plate and by the eng...

Page 12: ...tivated for a certain period of time resulting in less fuel consumption and low cab noise level Automatic engine shut down system Optional equipment Automatic engine shut down system is to stop the engine automatically when the machine is not operated for a certain period of time Automatic engine shut down conditions Control lockout lever is locked position Engine speed control switch is not chang...

Page 13: ...n of Roll Over Protective Structure Never carry out any unauthorized alterations to the cab for example lowering the roof height drilling welding on brackets for fire extinguisher radio aerial or other equipment without first having discussed the alteration with personnel at the Volvo Engineering Department This department will decide whether the alteration may cause the approval to become void It...

Page 14: ...k gearbox is composed of sun gear planetary gear pinion gear and housing Swing motor The swing motor consists of the rotary group of 9 fixed volume pistons cylinder blocks and a shaft with pinion gear the parking brake group with washer spring and piston and the control block group with an anti shock relief valve Main control valve The control valve consists of 10 or 11 for rotator option section ...

Page 15: ...llowing conditions is met 1 The attachment accessory assembly or part is manufactured or distributed by Volvo Construction Equipment and installed in a factory approved manner as described in the publications available from Volvo Construction Equipment or 2 The modification has been approved in writing by the Product Line Engineering Department of Volvo Construction Equipment Anti theft device An ...

Page 16: ... improved by knowing if machines are being operated correctly and how much fuel is being consumed CareTrack also allows the customer to restrict the operating area of the machine by using virtual fences This helps to eliminate unauthorized machine use and theft For further information contact a Volvo Construction Equipment dealer The CareTrack system transmits data in the same way a mobile phone d...

Page 17: ...m cylinder 14 Bottom roller 4 Dipper arm 15 Front cover 5 Bucket cylinder 16 Upper roller 6 Link 17 Track motor and gearbox 7 Bucket 18 Counterweight 8 Boom cylinder 19 Fuel tank 9 Boom swing cylinder 20 Hydraulic tank 10 Dozer blade cylinder 21 Rear cover 11 Dozer blade 22 Air compressor tank 16 Presentation Machine view ...

Page 18: ... 24 25 26 29 28 23 Rear view camera 27 Engine oil filling port 24 Engine air cleaner 28 Radiator Hydraulic oil cooler 25 Diesel particulate filter 29 Coolant expansion tank 26 Fuel filter Presentation Machine view 17 ...

Page 19: ...claration of Conformity issued by Volvo CE for each separate machine This EU declaration also covers attachments manufactured by Volvo CE The documentation is a valuable document which should be kept safe and retained for at least ten years The document should always accompany the machine when it is sold If the machine is used for other purposes or with other attachments than described in this man...

Page 20: ...ut of a safety point of view where permitted limits have been determined and given according to international standards A machine or device which meets the requirements should be CE marked Our machines have been tested particularly for electromagnetic interference The CE marking of the machine and the declaration of conformity also cover the EMC directive If other electronic equipment is fitted to...

Page 21: ...art 1 General requirements EN 474 5 2006 A1 2009 Earth Moving machinery Safety Part 5 Requirements for hydraulic excavators to which this declaration relates is in conformity with the Essential Health and Safety requirements of the Council Directive 2006 42 EC relating to Machinery Council directive 2000 14 EC relating to Noise Emission in the Environment by equipment for use out doors Council dir...

Page 22: ...ess and Date of issue Signature of authorized representative in the Community empowered to complete the manufacturing process and draw up declaration of conformity of the manufacturer only if applicable Signature block capitals Position or title Address and Date of issue This declaration includes attachments developed designed approved marked and marketed by above mentioned manufacturer The owner ...

Page 23: ...er XXXkW 6 Original technical documentation is kept by the Notified Body 1067 AV Technology Ltd AVTECH House Birdhall Lane Cheadle Heath Stockport SK3 0XU UK 7 Product Identification Number PIN VCECXXXXXXXXXXXXX 8 Year of manufacture XXXX 9 Sound values and separate directives Machine type XXXXXX Measured sound power value in dB A XXX Guaranteed sound power value in dB A XXX The Volvo EC ECR EW FC...

Page 24: ...ive good adaptation to the surroundings The antenna cable must be of the coaxial type Be careful to ensure that the cable is undamaged that the sheath and braid are not split at the ends the braid covers the connector ferrules and has good galvanic contact with them The mating surface between the antenna mounting bracket and the bodywork must have clean metal surfaces with all dirt and oxide remov...

Page 25: ...o fulfil a safety function Examples of safety classified machine parts spare parts Removable protective devices guards over rotating parts and hot surfaces Protective plates rails covers and steps Components included in systems to reduce sound and vibrations Components included in systems to improve the operator s visibility Complete operator s seat incl seatbelt Decals and plates Cab filter NOTE ...

Page 26: ...d or when ordering spare parts V1157225 3 4 2 1 1 Product plate This plate with Product Identification Number PIN for the complete machine indicates the model designation machine weight engine power manufacturing year and CE approval The plate is positioned on the right side of the superstructure 2 Engine The engine type part number serial number MFG date information are stamped on the top of valv...

Page 27: ...r supplier code rated capacity weight cutting width tooth part number and adapter part number 4 Cab The nameplate is attached on the inside of the cab and indicates the product number machine model cab serial number ROPS certificate number maximum machine mass and international standard 26 Presentation Product plates ...

Page 28: ...ls must be kept free from dirt so that they can be read and understood If a decal is lost or becomes illegible it must be replaced immediately The part number order number is given on the respective decals and in the Parts Catalogue NOTE The word WARNING is given on the warning decals for North America 2 4 20 35 22 26 11 29 6 37 8 12 9 30 30 27 26 27 26 8 9 32 21 3 14 9 17 24 34 1 33 25 19 18 23 1...

Page 29: ...ressure do not unscrew the recoil spring when tensioning tracks read the Operator s manual See page 265 4 WARNING Hot and pressurised coolant when opening radiator cap V1078504 5 WARNING When leaving the machine move the control lockout lever up to lock the hydraulic system 6 Lubrication and service chart See page 251 28 Presentation Information and warning decals ...

Page 30: ...de machine 8 Lifting point V1065381 V1129244 9 Tie down point 10 Emergency exit V1065366 V1079484 11 Coolant information read the Operator s manual See page 274 12 WARNING No smoking when fuel filling Presentation Information and warning decals 29 ...

Page 31: ...65370 15 WARNING Lock the front window 16 Machine position when checking hydraulic oil level V1065358 V1078496 17 WARNING Crushing area keep a safe distance from the machine Spare part number in USA 13935000 17 WARNING Crushing area keep a safe distance from the machine Spare part number in USA 13935000 optional 30 Presentation Information and warning decals ...

Page 32: ...r in USA 11026072 V1093043 V1125755 20 WARNING Before working after connecting and disconnecting attachment read the Operator s manual Attachment quick coupler option 21 Battery disconnect switch V1080697 V1159071 22 Fuel filler pump ON OFF 23 WARNING Control pattern selector optional See page 100 Presentation Information and warning decals 31 ...

Page 33: ...5 26 Notice attachment 27 Notice attachment V1077506 10 500 250 V1065371 ISO VG 68 28 Greasing interval read the Operator s manual 29 Type of hydraulic oil filled at factory optional V1078495 V1123383 30 WARNING Do not stay in the vicinity of a raised load 31 WARNING Overload warning button See page 86 32 Presentation Information and warning decals ...

Page 34: ...pedal functions optional 35 WARNING Risk of explosion read the Operator s manual See page 293 V1129275 MAX 500 ppm SULFUR V1065382 LONG LIFE HYDRAULIC OIL 36 WARNING Sulphur content information in the diesel fuel for China See page 304 37 Long life hydraulic oil Presentation Information and warning decals 33 ...

Page 35: ...d to loss of machine control and could cause serious injuries including death Carefully read through the Operator s Manual and learn the warning signs symbols and operating instructions before attempting to operate the machine V1157492 1 3 2 4 1 Left instrument panel 2 Front instrument panel 3 Right instrument panel 4 Rear instrument panel 34 Instrument panels ...

Page 36: ...eft optional equipment 3 Rotating beacon switch optional equipment 4 Air compressor switch optional equipment 1 Interior light switch Position 0 Cabin light is switched OFF Position 1 Cabin light is switched ON 4 1 3 2 V1159070 V1065651 0 1 Instrument panels Instrument panel left 35 ...

Page 37: ...achment quick coupler switch for initiating on the right instrument panel must be pressed first to activate this switch See page 86 194 for the operation Press down 1 Attachment quick coupler confirming control When the check message for confirming appears on the I ECU press the switch for more than 0 7 seconds to confirm that the attachment quick coupler is locked Then the buzzer sound will be tu...

Page 38: ...tating beacon when the swing system is activated 4 Air compressor switch This switch is used to operate the air compressor For more information see page 125 Position 0 Air compressor is OFF Position 1 Air compressor is ON NOTE The switch is returned automatically V1065629 0 1 V1079497 1 0 Instrument panels Instrument panel left 37 ...

Page 39: ...panel before trying to operate the machine NOTE The front instrument panel is designed to display one of the supported languages Refer to page 45 for details on how to set the language and the units V1134960 Adjustable direction of I ECU l 5 6 2 3 4 1 FLOW CLIMATE V1157500 1000rpm 1 Central warning light screen 2 Gauge screen 3 Engine speed screen 4 Mode screen 5 CCM Climate Control Module screen ...

Page 40: ...tely in order to avoid air entering the system Fuel tank capacity see page 309 B Engine coolant temperature gauge The gauge shows the temperature of the engine coolant and it has a red mark meaning engine overheated NOTE The red central warning light flashes if the coolant temperature becomes abnormally high Turn off the engine immediately and check the cause C Time Time segment displays the curre...

Page 41: ...e engine speed graph maximum four digit number When the engine is off engine speed is displayed as 0 NOTE Engine speed may vary according to the optional equipment 4 Mode Flow Shows LH and RH speed flow of selected options refer to page 45 for speed flow setting instructions V1158192 1000rpm 1 2 1 Engine speed step 2 Actual engine speed V1158801 1 l FLOW CLIMATE A B 1 Mode screen A Flow of Dozer b...

Page 42: ...r warning indicator and fixed indicator An indicator that has higher priority is put on the left side of the one that has lower priority Indicators on both sides can extend their display area to the other side if there is no indicator on the other side When the whole area is filled and there are more indicators to display indicators keep replacing the others so that the user can see all indicators...

Page 43: ...P Dozer float activated Automatic shutdown enabled V1158804 V1158805 Dozer blade enabled Rotator enabled V1159063 V1065465 X1 double acting enabled X1 single acting enabled V1159062 V1159065 Boom swing enabled Pipe laying mode enabled V1159066 Tilting enabled 42 Instrument panels Instrument panel front ...

Page 44: ... the bucket is still attached to the attachment bracket V1160715 V1065488 Quick coupler engaged Seat belt V1065480 V1065481 Wrong battery charge High engine coolant temperature V1065475 V1065486 Low engine oil pressure 11 Low fuel level V1065484 V1065478 Clogged engine air filter Low engine oil level V1065463 V1065483 Air preheating Control pattern error Instrument panels Instrument panel front 43...

Page 45: ...Fixed indicators V1065472 V1065473 SAE ISO Message indicator fixed position Pattern changer status fixed position V1065474 BHL Pattern changer status fixed position 44 Instrument panels Instrument panel front ...

Page 46: ...up for a few seconds B Daily maintenance The operator can see daily maintenance items once a day This screen is dismissed by pressing the ESC button or SELECT button and disappears automatically after 5 seconds if there is no button input V1159067 DAILY MAINTENANCE Engine oil level Coolant level Water separator Air cleaner Hydraulic oil level Travel working light Instrument panels Display unit 45 ...

Page 47: ... the camera views when operating the machine For detailed information about camera control see page 135 D Main screen After the initial camera screen is dismissed the main screen is displayed NOTE Indicator for seat belt will be displayed for 3 seconds on the Daily maintenance screen or main screen Fasten the seat belt before operating the machine V1170149 CLIM ATE Flow l FLOW CLIM ATE V1158196 10...

Page 48: ...essing the ESC button on the keypad Subscreens 1 Engine Oil pressure This shows the measured value of the engine oil pressure When the bar graph is green the value is OK within normal operation range When the bar graph is red the value is abnormal Barometer This shows the measured value of the barometric pressure V1158197 MENU Hydraulics Electrical system Machine information Vehicle messages Servi...

Page 49: ... regeneration progress Regeneration is complete when the bar graph reaches 100 Regen Start Stop This allows the operator to select regeneration start or stop using arrow buttons Refer to page 155 for more detailed information about regeneration V1147259 Engine DPF soot level 100 130 140 V1147260 Engine DPF Regen progress 0 100 V1194499 Engine Regen start stop Regen start stop Start Stop 48 Instrum...

Page 50: ...s where the machines need to be left running around the clock without operator presence To use this optional mode the parked regeneration mode should be selected in advance When selecting Enabled in this menu the parked regeneration is started automatically when needed without any further operator action This function will only be active while in parked mode regardless of regeneration mode and wil...

Page 51: ...is OK within normal operation range When the bar graph is red the value is abnormal 4 Machine information Serial number This shows the model serial number Operating hour This shows the machine s operating hours V1158199 Hydraulics Pump torque setting Max Min V1158200 Electrical system Voltage Low High V1158201 Machine information Operating hour 23 6 h Serial number XXXXXX 50 Instrument panels Disp...

Page 52: ...utton when the Yes value is highlighted Press the ESC button to Cancel Current fuel cons This shows the calculated fuel consumption at the current time Ambient temperature This shows the measured ambient temperature V1158202 Machine information Work timer 23 h 30 min Reset work timer Yes No Machine information Work timer 0 h 00 min V1158203 Machine information 15 0 L h Average fuel cons Reset fuel...

Page 53: ...n the Time remaining reaches 40 h 20 h and 0 h the check screen with Time remaining and Interval will pop up on the I ECU Service the maintenance items which should be serviced in that interval For the service interval and maintenance items see page 310 Reset After servicing the maintenance items the time can be reset Press ESC button to cancel or SELECT button to Yes When the time is reset Reset ...

Page 54: ... with Time remaining and Interval will pop up on the I ECU Service the maintenance items which should be serviced in that interval For the service interval and maintenance items see page 310 Reset After servicing the maintenance items the time can be reset Press ESC button to Cancel or SELECT button to Yes When the time is reset Reset time remaining will be displayed to Change interval Service Fue...

Page 55: ...h Reset time remaining and Interval will pop up on the I ECU Service the maintenance items which should be serviced in that interval For the service interval and maintenance items see page 310 Reset After servicing the maintenance items the time can be reset Press ESC button to Cancel or SELECT button to Yes When the time is reset Reset time remaining will be displayed to Change interval Service H...

Page 56: ...screen with Time remaining and Interval will pop up on the I ECU Service the maintenance items which should be serviced in that interval For the service interval and maintenance items see page 310 Reset After servicing the maintenance items the time can be reset Press ESC button to Cancel or SELECT button to Yes When the time is reset Reset time remaining will be displayed to Change interval Servi...

Page 57: ... be shown on I ECU when boom swing function is selected For more information regarding boom swing see page 38 for flow display and see page 86 100 for operating LH speed This is to preset left boom swing speed RH speed This is to preset right boom swing speed Response mode The operator can adjust the movement sensitivity of Boom swing when operating the levers Active mode is the most sensitive Act...

Page 58: ...t can be activated For more information see page 86 and 100 HAMMER SHEAR Adjust tool setting This is to preset the X1 setting so that operators can use it simply by selecting the tool from the Select work tool V1158211 Setup X1 X1 Select work tool Adjust tool setting New Hammer Shear Select work tool X1 Select work tool Adjust tool setting New Hammer Shear Adjust tool setting V1158330 Instrument p...

Page 59: ...referred control type using the arrow buttons Save the selected item using the SELECT button Use ESC button to cancel without saving For information on control types see page 85 LH speed This is to adjust shear LH speed RH speed This is to adjust shear RH speed Response mode The operator can adjust the movement sensitivity of shear when operating the levers Active mode is the most sensitive V11583...

Page 60: ...ght or left to select next character Press the SELECT button to save the name Use the ESC button to get out of screen without save 3 Select Adjust tool setting and then choose the new tool which is newly created X1 Select work tool Adjust tool setting New Enter tool name VOLVO New work tool V1158334 V1158335 Setup X1 X1 Select work tool Adjust tool setting New Hammer Shear VOLVO Adjust tool settin...

Page 61: ...nd then choose the new tool which is newly created Name VOLVO Acting direction 2 way Control type Proportional LH speed VOLVO Max Min V1158336 RH speed Response mode Active Max Min V1158337 Setup X1 X1 Select work tool Adjust tool setting New Hammer Shear VOLVO Select work tool 60 Instrument panels Display unit ...

Page 62: ...g speed This is to preset raising speed of dozer blade Lowering speed This is to preset lowering speed of dozer blade Response mode The operator can adjust the movement sensitivity of dozer blade when operating the levers Active mode is the most sensitive V1158338 Setup X1 X1 Select work tool Adjust tool setting New Delete Hammer Shear VOLVO Delete setting Raising speed Dozer blade Max Min V115833...

Page 63: ...e of X3 tools form list When operator push the X3 dozer blade button on keypad and then push the selection button on the left operating lever X3 tool which is selected from list can be activated See page 100 for more information Adjust tool setting This is to preset control type operating speed and response mode of X3 tool V1158340 Setup X3 X3 Select work tool Adjust tool setting New Rotator Selec...

Page 64: ...DOWN button to select the characters A B Z 0 1 9 Use the arrow right or left button to select next character Press the SELECT button to save the name Use the ESC button to get out of screen without save RH speed Response mode Active Max Min Name Rotator Control type Proportional LH speed Rotator Max Min V1158342 X3 Select work tool Adjust tool setting New Enter tool name VOLVO New work tool V11583...

Page 65: ...l type LH speed and RH speed according to new tool V1158344 Setup X3 X3 Select work tool Adjust tool setting New Hammer Shear VOLVO Adjust tool setting Name VOLVO Acting direction 2 way Control type Proportional LH speed VOLVO Max Min V1158345 RH speed Response mode Active Max Min 64 Instrument panels Display unit ...

Page 66: ... mode if the Auto idle button is ON and any of control levers pedals or engine speed control switch are not operated for a certain time See page 86 for more information regarding Auto idle button on keypad V1158346 Setup X3 X3 Select work tool Adjust tool setting New Hammer Shear VOLVO Select work tool V1158347 Setup Wiper interval Wiper interval Set wiper interval 4 s V1137900 Setup Auto idle tim...

Page 67: ...is menu is used for setting up the anti theft system Owner menu The machine owner s PIN code is required to access this menu V1158348 Setup Auto shutdown Auto shutdown timer Set timer OFF Pin code menu Pin code menu Owner menu Setup Anti theft system Enter owner PIN code Read PIN code Generate random PIN Set PIN code Service action V1191921 66 Instrument panels Display unit ...

Page 68: ...ti theft system except for remote immobilization no coverage immobilization and machine serial number check and the WECU informs the CareTrack portal The anti theft system will be activated when the ignition is turned on the next time See page 76 for information V1160928 1 2 3 4 Read PIN code Generate random PIN Set PIN code Service action PIN Code V1169029 2 3 4 5 Read PIN code Generate random PI...

Page 69: ...see page 100 Language Supported languages are listed in the screen in the form of their own languages Use the arrow buttons to scroll up and down to find your specific language Press the SELECT button to select the chosen language The screen reverts to the former screen displaying the newly selected language V1158349 Setup Overload pressure Overload pressure Set overload pressure 70 V1158485 Setup...

Page 70: ...and save it by pressing SELECT button The units stored in the I ECU are as follows Item Metric US Time h h Fluid rate l h g h Volume L G Voltage V V Current A A Temperature C F Revolution rpm rpm Speed km h mph Pressure bar psi Distance km mile V1137904 Setup Units Units Metric US Instrument panels Display unit 69 ...

Page 71: ...for adjusting the date The preset date format is shown in the first row of the screen The operator can adjust the date with arrow ESC and SELECT buttons Arrow buttons are used to adjust each segment of the date SELECT and ESC buttons are used to save or cancel V1158486 Setup Time date Set time Set date Set time format Set date format Time date V1158487 Time date Set time 24 h 17 01 Set time V11379...

Page 72: ...lled with the arrow buttons and the value is set with the SELECT button Keypad backlight The brightness of the keypad backlight is changed by the adjustment The adjusting bar in the screen is controlled with the arrow buttons and the value is set with the SELECT button V1158489 Time date Set time format 24 12 Set time format V1158490 Time date Set date format yy mm dd mm dd yy dd mm yy Set date fo...

Page 73: ... pressing the SELECT button to view detail information about a headline the displayed information replaces the whole main screen The information content includes Fault Active Error Code Source First Event No of events Last event V1160717 Setup Camera screen Camera screen Original image Mirror image V1137911 Vehicle messages Engine system Check at next stop System failure Engine system Fault Active...

Page 74: ... shown for seven seconds and then changes to operating display Repair or contact a workshop authorized by Volvo for information Table Example of information screen Check at next stop Deck light relay failure Reverse light failure Boom light relay failure Rear light relay failure Front light relay failure Wiper motor relay failure Washer pump relay failure Cabin temp sensor failure Ambient temp sen...

Page 75: ...al switch failure Boom swing X1 disabled ELEC DBLD X3 disabled X1 double acting valve failure X1 single acting valve failure X1 disabled X1 disabled E ECU not responding I ECU not responding Communication failure Communication failure Keypad not responding CCM not responding Communication failure Communication failure Starter relay failure Conflux cutoff valve failure Lifting mode inoperable Boom ...

Page 76: ...orized by Volvo for information Table Example of warning screen Stop machine Check the component Pattern change valve failure Pump torque limit PPRV failure System voltage high System voltage low Overload sensor failure I ECU failure Emission deterioration E ECU failure Engine power derated Engine overrun Engine overheat Engine power derated Contact service Regen inhibited System failure Prepare s...

Page 77: ... the authorization code display is shown if the anti theft system is selected as an optional equipment Wrong code display appears on the I ECU when the operator or machine owner has entered the wrong code After 3 inputs of an incorrect code the authorization will be limited for 5 minutes and a wrong code alarm will send to the CareTrack portal The default code lock s delay time is 2 minutes and it...

Page 78: ...ivates a geofence in the CareTrack portal and the machine is outside the geofence the geofence broken message will appear on the I ECU When the machine owner activates a geofence and configures automatic immobilization in the CareTrack portal and the machine is outside the geofence the geofence broken warning message will appear on the I ECU and the machine is immobilized at the next stop WECU sen...

Page 79: ...on the V ECU informs the operator with the warning message on the I ECU and activates machine immobilization GSM 3G tampered If someone cuts the GSM 3G antenna the V ECU informs the operator with the warning message on the I ECU and activates machine immobilization Open box detection If someone tries to open the WECU enclosure the V ECU informs the operator with the warning message on the I ECU an...

Page 80: ... message will appear on the I ECU WECU sends the warning message to the CareTrack portal The warning condition is revoked when the trigger has disappeared Remote immobilization If dealer level 3 code owner requests machine immobilization in the CareTrack portal the remote immobilization warning message will appear on the I ECU and the machine is immobilized at the next stop If machine owner reques...

Page 81: ... machine is turned on the WECU and V ECU check the machine serial number of the other ECUs If the machine s serial number is different the V ECU prevents machine start immediately and a warning message will appear on the I ECU If the WECU is disconnected from key on cable and the machine is turned on the V ECU prevents machine start immediately and a warning message will appear on the I ECU The wa...

Page 82: ...attery and disconnecting the GPS antenna This disables the anti theft system except for remote immobilization no coverage immobilization and machine serial number check and the WECU informs the CareTrack portal The anti theft system will be activated when the ignition is turned on the next time V1160927 0 Pin code menu One time code Pin code menu Owner menu Enter owner PIN code V1160928 1 2 3 4 Re...

Page 83: ... seed number shown on I ECU and machine serial number Alarm texts for anti theft system Information The blue information symbol is shown The buzzer sounds two times Alarm text is shown for seven seconds and then changes to operating display V1137933 Geofence broken GO BACK TO SITE V1137935 Timefence broken Go back to site Geofence broken Timefence broken V1160932 7 4 0 9 7 1 2 Current 8 digit seed...

Page 84: ... next stop Geofence broken Immobilization at next stop Timefence broken Immobilization at next stop Anti Theft system tampered Immobilization at next stop V1139554 No coverage Days before immob XXX V1137942 No coverage Immobilization at next stop V1137939 Remote immobilization activated by level 3 Immobilization at next stop No coverage Days before immob No coverage Immobilization at next stop Rem...

Page 85: ...te immobilization No coverage V1160926 Electronic system tampered Contact service Machine inoperable Machine immobilized Geofence broken Timefence broken System tampered Machine movement Battery power lost Remote immobilization No coverage Contact service Electronic system tampered Machine inoperable V1155510 Anti Theft system tampered Machine immobilized Contact service V1160719 Electronic sys po...

Page 86: ...the on off switch is pressed On position The function will be deactivated when the on off switch is released Control using proportional switch on the control lever 1 Toggle and Push button type in the I ECU These controls with proportional switch are similar as the ones with on off switch but it has a special point to activate the actuator because the proportional switch also has a proportional va...

Page 87: ...de control lever 8 Ignition switch 9 Power socket 10 Service socket 1 Travel speed switch Position 0 Travel at LOW speed only Position 1 Travel at LOW or HIGH by automatic shift according to travel condition NOTE Low speed should be selected for grades on soft ground in restricted spaces and when the machine is loaded onto or unloaded from a transport vehicle V1194496 1 2 3 4 5 6 7 8 9 10 V1065624...

Page 88: ...ent panel must be pressed to open the attachment quick coupler See page 35 194 for operation After installing the attachment quick coupler press the switch to position 0 to close the attachment quick coupler When the switch is in position 0 the buzzer sounds and the check message for confirming and indicator are displayed on the I ECU NOTE Press the attachment quick coupler switch on the left inst...

Page 89: ...on 16 Dozer blade floating button 17 Overload warning button 18 Washer button 19 X3 Dozer blade activating button 20 X1 boom swing activating button 1 Camera button if installed This button is used to control the camera screen in the I ECU A short press on the camera button shows the camera view For detailed information about the camera control see page 135 2 HVAC control button This button is use...

Page 90: ...tton is used to control the HVAC system See page 118 5 Arrow up button This button is used to scroll between items and adjust each segment on the screen 6 Defroster select button This button is used to activate the defroster See page 118 7 Arrow left button This button is used to move the cursor to the left Also press the button in order to decrease values 8 Arrow down button This button is used t...

Page 91: ...ning the control switch clockwise Reduce the engine speed by turning the control switch counter clockwise Power max mode switch Press down switch A to activate power maximum mode If the machine is not operated in P mode for more than 5 seconds and the auto idle selector switch is activated the engine speed automatically goes down to idle mode When the machine is operated again it returns to P mode...

Page 92: ...rd digging and trenching 9 2200 2200 8 2000 2000 For economical operation during general applications 7 1850 1850 6 1750 1750 5 1600 1600 4 1500 1500 3 1400 1400 2 1250 1250 For maximum lifting power and moderate control 1 1000 1000 For low idle warm up and very precise operation Instrument panels Instrument panel right 91 ...

Page 93: ...activated automatically whenever the ignition switch is on It is used to warn people in the surrounding area when the machine is moving NOTE When starting the machine travel the travel alarm always sounds for 5 seconds even though the travel alarm stop function is activated 15 Windshield wiper button This button is to activating windshield wiper Operator can adjust wiper interval See page 45 for s...

Page 94: ...ressed When the event occurs again when operating the machine A warning alarm sounds and the indicator is shown When reducing the load the alarm and indicator will turn off 18 Washer button This button is to work washer 19 X3 dozer blade activating button This button is used to activate the X3 dozer blade function NOTE This instruction can be changed according to the types of operating lever For m...

Page 95: ...It searches the higher frequencies automatically and stops at a receivable frequency Music select button forward It selects the next song in the play list in your cell phone 4 Power on off Mute toggle button Press the button to turn On Off the audio power and to change between Mute Output Press shortly Mute Press shortly Unmute Keep pressing the button Power off 5 Volume down button Press the butt...

Page 96: ... a conversation the light is on with fixed green Not calling Calling In calling Hanging up Flashing phone ringing Answering Keep pressing the button while flashing Rejecting Call function of the button above calls the previous number 8 Bluetooth button optional equipment By pressing this button the following functions will work according to the machine s Bluetooth connection status Not connected R...

Page 97: ...e preheating system When the ignition switch is turned to position 1 the machine s electronic system will be active thus activating the automatic engine preheating system Start position 2 When the ignition switch is turned to position 2 the starter motor will be engaged to crank the engine provided that the battery disconnect switch has been activated The starter motor will not crank as long as th...

Page 98: ...socket is for electrical appliances such as a mobile phone charger Capacity under 12 V 4 A 10 Service socket This socket is for Volvo s service tools such as Tech tool or MATRIS Instrument panels Instrument panel right 97 ...

Page 99: ...Instrument panel rear Audio system optional equipment See page 126 98 Instrument panels Instrument panel rear ...

Page 100: ...avel pedals 5 Dozer blade lever The control levers of this machine is set from factory to operate in ISO SAE standard operating pattern for optimum machine performance On machines equipped with the electric pattern change the indicator of chosen pattern will be shown on the I ECU Other controls 99 ...

Page 101: ...Unfamiliar control patterns could cause confusion and accidents resulting in serious injury Use extreme caution when using the control levers after changing the control pattern and until you become familiar with the new pattern NOTICE Selected control pattern is shown on the front instrument panel It is important to check this before using the machine 100 Other controls Controls ...

Page 102: ... arm out N Neutral superstructure and dipper arm in neutral position 2 Dipper arm in 1 Dipper arm out 3 Left swing 2 Dipper arm out and swing superstructure right 4 Right swing 3 Swing superstructure right 4 Dipper arm in and swing superstructure right 5 Dipper arm in 6 Dipper arm in and swing superstructure left 7 Swing superstructure left 8 Dipper arm out and swing superstructure left Other cont...

Page 103: ...tion 2 Boom raise 1 Lower boom 3 Left swing 2 Lower boom and swing superstructure right 4 Right swing 3 Swing superstructure right 4 Raise boom and swing superstructure right 5 Raise boom 6 Raise boom and swing superstructure left 7 Swing superstructure left 8 Lower boom and swing superstructure left 102 Other controls Controls ...

Page 104: ...ine performance ISO SAE control pattern V1158497 1 3 2 2 4 1 Bucket in N Neutral boom and bucket in neutral position 2 Bucket out 1 Lower boom 3 Boom lower 2 Lower boom and bucket out 4 Boom raise 3 Bucket out 4 Raise boom and bucket out 5 Raise boom 6 Raise boom and bucket in 7 Bucket in 8 Lower boom and bucket in Other controls Controls 103 ...

Page 105: ...and dipper arm in neutral position 2 Bucket out 1 Dipper arm out 3 Dipper arm out 2 Dipper arm out and bucket out 4 Dipper arm in 3 Bucket out 4 Dipper arm in and bucket out 5 Dipper arm in 6 Dipper arm in and bucket in 7 Bucket in 8 Dipper arm out and bucket in 104 Other controls Controls ...

Page 106: ...control lever 1 Horn button 3 Operating switch for hydraulic breaker hammer 2 Unassigned 4 Function selector switch for boom swing or X1 a or open and closing attachments b 5 Operating switch for boom swing or X1 or open and closing attachments Boom swing to left Boom swing to right Attachmen t opens Attachmen t closes Hammer a X1 can be one of hydraulic breaker hammer or Shear Select work tool at...

Page 107: ... hammer 4 Operating switch for dozer blade or X3 7 Operating switch for boom swing or X1 or open and closing attachments Dozer down Dozer up Boom swing to left Boom swing to right Rotate to left Rotate to right Attachme nt opens Attachme nt closes Hammer a Rotator optional equipment Select work tool at I ECU MENU Setup X3 b X1 can be one of hydraulic breaker hammer or Shear Select work tool at I E...

Page 108: ...aker hammer 4 Operating switch for dozer blade or X3 a 7 Operating switch for boom swing or X1 or open and closing attachments Dozer down Dozer up Boom swing to left Boom swing to right Dozer angle Dozer angle Attachme nt opens Attachme nt closes Rotate to left Rotate to right Hammer a Rotator optional equipment Select work tool at I ECU MENU Setup X3 b X1 can be one of hydraulic breaker hammer or...

Page 109: ...ch 1 is assigned to dozer blade select dozer blade up down or angle using switch 5 NOTE Selected function can be checked by function indicator on I ECU See page 38 Step 3 Operation 1 Operating switch 2 for dozer blade or X3 3 Operating switch 4 for boom swing or X1 NOTE For operating boom swing function remove pin C with clip D near the boom support mounting pin If not using boom swing function pi...

Page 110: ...n digging Unexpected movements may otherwise occur If you want to travel the machine continuously keep in mind below operating conditions Ground conditions Operation Flat normal or soft soil Do not travel continuously for more than 2 hours If you want to travel for more than 2 hours at high speed stop for more than 20 minutes Otherwise tracks rollers and idlers can be overheated to cause oil leaka...

Page 111: ...he machine stops Left turn When the sprockets are at the rear side of the machine Push the right lever forward the right track rotates forward and the machine travels forward as it turns to the left Pull the left lever backward the left track rotates in reverse and the machine travels backward as it turns to the left Right turn When the sprockets are at the rear side of the machine Push the left l...

Page 112: ...ile the float function is activated When the dozer blade reaches the stroke end the dozer blade will not drop down immediately exception if angle dozer blade is equipped To get away from this condition lower the dozer blade a little bit Because the pressure can be dissipated by inherent internal leakage do not leave the dozer blade up for a long time while the float function is activated V1158612 ...

Page 113: ...scattering materials are capable of entering the operator s cab Install front guards when working with a breaker In mining applications FOPS must be adopted The above recommendations are based on standard working conditions Install necessary additional protection guards in accordance with job site conditions and local government regulations Contact authorized Volvo CE dealer to meet local regulati...

Page 114: ...ront window 3 Fasten the bolts A with regulated torque by pushing the FOG Tightening torque and weight Bolts A 11 3 1 1 kgf m 81 59 8 0 lbf ft FOG weight 123 kg 271 lb FOPS weight 75 kg 165 Ib A A C B V1158615 D A Bolts B C FOG Falling Object Guard C FOPS Falling Object Protection Structure D Safety net Other controls Cab 113 ...

Page 115: ...ed but the control levers and pedals for working and travel hydraulics are locked no movement possible Position B Shift the control lockout lever to position B The engine cannot be started but the control levers and pedals for working and travel hydraulics are unlocked working and travelling position NOTE If the control lockout lever is set to locked position while operating the machine the engine...

Page 116: ...ement of machine or parts This could result in serious injury Always lock the control lock out lever before adjusting the seat NOTICE Installation and maintenance of the operator seat may only be carried out by authorised and competent personnel NOTICE To obtain maximum comfort and eliminate the risk of accidents you must make sure that all seat adjustments have been carried out correctly before s...

Page 117: ... the backrest to desired position Let go of the lever and make sure the backrest is properly engaged Seat heating switch optional equipment This is used to warm up the operator seat The seat heating will activate when this switch is in position 1 and the temperature is under 10 C 50 F The seat heating stops when the temperature is up to 20 C 68 F and will activate again when the temperature turns ...

Page 118: ...ep the belt rolled up when not in use WARNING Risk of serious injury or death A damaged seat belt could cause serious injury or death Check the seat belt and associated parts before start of machine operation Check the seat belt and associated parts daily Ensure mounting hardware is tight Replace the entire seat belt immediately if there is any wear the webbing is worn cut has loose stitching the ...

Page 119: ... is turned off Press and hold in the button to setup the HVAC system 2 Arrow up button This button is used to scroll between items and adjust each segment on the screen 3 Defroster select button Press the button to activate the defroster Fresh air mode is selected automatically NOTE After 20 minutes this setting is automatically returned to the previous mode 4 Arrow right button This button is use...

Page 120: ...or selecting climate mode auto manual or defrost Mode selection and fan speed in manual mode are controlled with the arrow left or arrow right button B Temperature control Auto mode Temperature can be adjusted with the arrow left or arrow right button Default setting value is 22 C 71 6 F and the setting range is 16 C 32 C 60 8 F 89 6 F If the temperature sensor in cab fails auto mode shall turn of...

Page 121: ...opening 1 Lower the attachment to the ground and stop the engine 2 Push in the knobs on both handles 3 Pull the window backwards and push it up against the roof until it locks at both ends Front window closing 1 Lower the attachment to the ground and stop the engine 2 Push in the knobs on both handles 3 Pull the window down and push it forward until it locks at both ends Door It is used for keepin...

Page 122: ... front and roof sun shades to protect from the sun light coming in through windows Hour meter The hour meter shows the total number of hours the engine has operated It records the hour only when the engine is running V1077809 V1158618 V1158619 Other controls Operator comfort 121 ...

Page 123: ...A storage compartments are located at the right and rear side of operator seat NOTE Do not store tools in the storage compartment This could damage the compartment Cup and drink holder Use the cup and drink holder to hold a soft drink can in place V1158620 V1158621 V1158622 122 Other controls Operator comfort ...

Page 124: ... Operator s manual storage is located at the backside of seat Keep the manual in the storage so that it is always at hand Fire extinguisher location optional equipment Mount fire extinguisher as follows Remove two screws installed on the left rear side of cab and then install the fire extinguisher V1158623 V1158624 Other controls Operator comfort 123 ...

Page 125: ...TICE The hammer must not be removed from its position or be used at other occasions than in an emergency situation If the hammer should be lost it must be replaced immediately NOTICE There is a knife on the hammer for the emergency exit Cut off the seat belt with the knife if the buckle cannot be undone V1158625 1 2 1 hammer 2 Rear windshield 124 Other controls Operator comfort ...

Page 126: ...he dust with the air gun NOTE The air gun is stored inside the cab Caution for operation Never use compressed air for cleaning clothes or persons WARNING Risk of serious injury Compressed air water jets or steam may cause damage to unprotected skin and eyes Always wear personal protective gloves goggles and clothing when using compressed air water jets or steam Do not touch the surface of compress...

Page 127: ...cting a phone call 13 Phone button answering a call voice dialing 1 SRC button Select memory bank or audio source Short press Switch among radio USB AUX source Long press Activate Travel Store function in radio mode Setting kept in FMT or AMT memory bank NOTE Radio is switched on as FM1 FM2 FMT MW LW AM or AMT MW LW AM or AMT are only available in respective tuner regions NOTE AMT in tuner regions...

Page 128: ...ton In the menu Change menu level Radio mode Adjust the stations Other operating modes Track selection 6 MENU button Short press Close menu Long press Start scan function 7 USB socket 8 AUX 9 DISP button Switch display 10 Preset button 1 5 Short press Call up the stored station in radio mode Long press Store station on the current memory bank in radio mode 11 SD card slot 12 Phone button Red Endin...

Page 129: ...ly press the MENU button to open the user menu 2 Press the button until the TUNER menu item is selected 3 Press the Λ V button until the AREA menu item is selected 4 Press the button to set the reception area 5 Press the button to confirm the selected area iPod mode This audio system can play audio from iPod iPhone device via USB socket 1 Insert the iPod via USB extension cable in USB socket 2 Pre...

Page 130: ...t the browse mode It will show current playing tracks stored in the iPod press button to view all category Press the Λ V button once or several times to select a different folder Press the button to display the tracks of the selected folder The first track of the folder is shown on the display NOTE Press the button returns you to the folder list Press the Λ V button once or several times to select...

Page 131: ...technology is a wireless connection of short range For this reason Bluetooth devices must be located near the audio sound system in the machine to establish and maintain a connection To establish a Bluetooth connection you must first pair the audio sound system and the Bluetooth device When you pair the devices a Bluetooth connection is subsequently established automatically This connection remain...

Page 132: ... device registered first is unregistered 1 In the Bluetooth menu select the PAIRING menu item 2 Press the button The display shows PAIRING and the Blue tooth symbol is flashing The audio sound system can now be recognized by a Blue tooth cell phone approx 2 minutes and connected 3 Search Bluetooth name Volvo from your cell phone As soon as the audio sound system is located by the cell phone and is...

Page 133: ...treaming device 3 Turn the volume control to select a digit for the respective position 4 Press the or button t to reach the next or previous position 5 Press the button repeatedly until you reach past the last position to confirm the PIN entered 6 Search the audio sound system from your streaming device Bluetooth name Volvo and establish the connection Enter the PIN of the car sound system if nec...

Page 134: ...level meter 2 is moved to the next level AUX operation 1 Press AUX button 6 while the power is ON and the audio sound is transmitted outside NOTE Audio power has to be ON and voice is not transmitted outside in AUX operation 2 Press AUX button 6 once more and the AUX operation is released 3 The sound tone transmitted outside is adjusted with audio volume If the audio input is high the sound tone i...

Page 135: ...the volume is turned 12 clicks volume level meter 2 is moved to the next level Caution for operation Mike D is attached with a magnet on the left side in the cab If the location of the mike is changed the mike could fall down or be damaged by vibration while operating the machine Therefore put the mike on indicated location after using it NOTE The microphone s use could be restricted on general ro...

Page 136: ...s used as aids for better visibility 3 Rear view camera if installed NOTE Any modifications done to the machine that affect the operator s visibility must be verified by a Volvo dealer Camera system if installed The camera screen in the I ECU A is opened by pressing the camera button B on the keypad The camera button is illuminated when the camera view is displayed V1177358 1 2 3 Mirrors and camer...

Page 137: ...national regulations applicable to road safety and labour welfare Alertness judgement and respect for applicable safety regulations are conditions for avoiding risk of accidents Running in instructions During the first 100 hours the machine should be operated with a certain care It is important to check oil and fluid levels often during the running in period 136 Operating instructions ...

Page 138: ...ement For example NOTE Some parts of the basic machine may restrict visibility for example the cab s pillars frames exhaust pipe engine hood as well as optional equipment such as buckets pallet forks grapples and so on The load that is handled with these attachments may also restrict visibility Ensure that operators and job site workers have received thorough safety instructions Control the traffi...

Page 139: ... for determining if additional devices for indirect visibility such as warning systems are necessary The test was performed on machines with standard equipment and attachment If the machine is modified or fitted with other equipment or attachment which results in impaired visibility it should be re tested according to ISO 5006 If other equipment or attachments are used and the visibility has been ...

Page 140: ...perator see figure below NOTE Camera may be also used to create visibility on the rectangular boundary Camera is not adjustable on the machine V1177413 A B C D Close up visibility boundary according to ISO 5006 thick line A Refer to the table below B 1 0 m 39 4 in C 1 0 m 39 4 in D 1 0 m 39 4 in Test object height Region of the rectangular boundary A Front side Left side Right side Rear side 1 0 m...

Page 141: ...r view mirrors until good visibility is obtained see figures V1177416 Machine s top view Rear view camera if installed Check the rear view camera s display screen which is focused on the visible area for good visibility NOTE Camera is not adjustable on the machine V1177418 Machine s top view V1177414 Machine s right view V1177415 Machine s left view V1177417 Machine s left view 140 Operating instr...

Page 142: ... are working correctly Check if the management has established rules or procedures for the work site Always pay attention around the machine to identify any obstacles Prevent persons from entering or remaining in the work area i e the area around the machine and at least 7 m 23 ft beyond the maximum reach of the attachment However depending on the job site s organization the operator may allow a p...

Page 143: ... should undergo adequate training on the machine The operator must follow the rules and recommendations in the Operator s Manual but must also pay attention to any legislation and national regulations or specific requirements or risks that apply at the work site The operator must be thoroughly rested and must never operate the machine when under the influence of alcohol medicine or other drugs The...

Page 144: ...may allow a person to remain in the work area but must then observe caution and operate the machine only when the person can be seen or has given clear indications of where he or she is Prevent persons from being in the cab of a vehicle that is in a location with a risk that the cab may be hit by other machines or falling objects for example stones or logs This does not apply if the cab is suffici...

Page 145: ...xternal aerial fitted according to the instructions of the manufacturer Always sit in the operator seat when starting the engine machine Keep your hands away from areas where there is a risk of crushing for example covers door and window Always use the lap type seat belt or the three point belt if the machine is equipped with this Use steps and handholds when entering or leaving the machine Use th...

Page 146: ...orm passes Do not touch controls or anything metal In all kinds of works travelling digging loading hammering and so on place the idler side in front to reduce the travel drive damage due to incorrect operating position When DPF regeneration Make sure that there is no flammable material around the machine this is important to prevent risk of fire Move the machine to safety area if there is a risk ...

Page 147: ...ed When moving the machine with a suspended load special attention must be observed when required request the help of a signal man Warning beacon may by used On attached or connected implement which is wider than the vehicle itself When the vehicle constitutes a hindrance or danger to other traffic When working on or by the side of the roadway 146 Operating instructions Safety rules when operating...

Page 148: ... loose parts or leaks which can cause damage Check that the battery disconnected switch is switched on Check for cracks on frame and tracks Check that hoods and covers are closed Make sure fire extinguisher if equipped is fully charged Inspect steps and handholds for damage or loose parts Make necessary repairs if needed Check that there are no persons in the vicinity of the machine Adjust the ope...

Page 149: ...op position and wait a couple of minutes before the next starting attempt NOTICE If the engine sounds or runs strangely or if strong vibrations arise the ignition switch must be turned to stop position immediately NOTICE Wait until the electronic system is completely shut down before restarting 1 Turn the engine speed control switch A to the low speed position and turn the key to operating positio...

Page 150: ...en the engine has started 6 Check the travel lights and work lights If a travel alarm is installed check this function 7 Warm up the machine Run at low speed and with a light load until the oil in the engine and hydraulic system has warmed up NOTICE Run the engine at low idling speed for 10 15 minutes to warm the engine and the hydraulic system at temperatures below 15 C 5 F before putting the mac...

Page 151: ...t be turned off NOTICE Do not attempt to start the engine while the battery charger is still connected to the mains This may cause serious damage to the electronic control units 1 Turn OFF the battery disconnect switch 2 Remove the protections from the battery pole studs Connect two 12 V batteries as follows 3 Connect one of the jump leads between terminal on the battery of the machine and the ter...

Page 152: ... the chassis connection on the machine and then disconnect the other end of the jump lead from the terminal on the booster battery 9 Finally disconnect the jump lead between the terminals 10 Re install the battery pole stud protections Warming up Machine may respond slowly at low temperatures Operate carefully until the system has reached normal temperature Otherwise unexpected movements may occur...

Page 153: ...OTE Operate the machine functions travel swing and attachments very slowly and carefully WARNING Risk of crushing injury The hydraulic system could respond slowly at low temperatures and could cause unexpected machine movements Operate carefully until the hydraulic system has reached operating temperature NOTICE Do not rush warming of the oil since forced warming can damage the machine WARNING Ris...

Page 154: ...ibute the warmed hydraulic oil to all hydraulic cylinders and motors Carry out these movements until the hydraulic system has reached working temperature rapid working movements Travelling a short distance Moving the machine a short distance for example when loading onto or off a trailer must be done slowly with great care Under these conditions the engine speed must not exceed 1 200 rpm and the t...

Page 155: ...t this inclination as the machine may become unstable and unbalanced depending on the load NOTE Do not jack the track up more than 35 degrees using attachment Otherwise counterweight can be damaged NOTE If the machine is equipped with travel warning system a warning alarm sounds when levers or pedals are actuated For more operating information see page 100 154 Operating instructions Operating ...

Page 156: ...n of the aftertreatment system on a machine run on diesel fuel with high sulfur content The purpose of regeneration is to raise the temperature in the aftertreatment system so that any trapped substances are burned off to allow the system to regain its full capacity Normal operation During normal operation passive regeneration occurs continuously Automatic regeneration Automatic regeneration is pe...

Page 157: ...d is raised during a parked regeneration It is not advisable to cancel a parked regeneration which is in progress except in an emergency To start a parked regeneration Operator must stop the machine Put the control lockout lever to lock position and then select the Start menu on I ECU Menu Engine Regen start stop Start NOTE The operator can start the regeneration immediately by pressing the SELECT...

Page 158: ...ne while the HEST lamp is on NOTE The machine must be in an area that is not sensitive to heat while the symbol is lit Service regeneration If a requested regeneration is delayed for too long the PM particulate matter load in the DPF diesel particulate filter will be too high for a safe parked regeneration Then regeneration must be started with Volvo s service tool in order to perform a safe regen...

Page 159: ...of delaying regeneration engine derate higher fuel consumption shorter diesel particulate filter service life damage to the aftertreatment system Cancelling dynamic or parked regeneration NOTE Only cancel in an emergency 1 Select the Stop menu on I ECU Menu Engine Regen start stop Stop An alarm indication on the instrument panel confirms that regeneration has been cancelled Regeneration is cancell...

Page 160: ...ases during the entire regeneration process Start regeneration Parked regeneration possible Press SELECT to start Warning amber buzzer sounds amber central warning on 1 Park the machine in a non heat sensitive area Move the control lockout lever to locked position 2 Start regeneration NOTE Regeneration is cancelled if the control lockout lever is set to unlocked position NOTE The idle speed increa...

Page 161: ...mber central warning on engine derate is activated but is restored after a completed regeneration 1 Park the machine 2 Restart regeneration when possible Regeneratio n cancelled Derate active Warning amber V1135633 buzzer sounds amber central warning on engine derate is activated but is restored after a completed regeneration 1 Restart regeneration when possible 160 Operating instructions Exhaust ...

Page 162: ...ning red buzzer sounds red central warning on engine performance is significantly reduced 1 Park the machine in a non heat sensitive area Move the control lockout lever to locked position 2 Switch off the engine 3 Contact a Volvo approved workshop to have the diesel particulate filter replaced NOTE The soot load can only be reset by authorised Volvo personnel Continue operation Low temperature Reg...

Page 163: ... length of time the battery disconnect switch should be turned off Keep in mind that the theft and burglary risk can be minimised by Removing the ignition switch when the machine is left unattended Locking doors and covers after working hours Turning off the current with the battery disconnect switch and removing the handle of the switch Parking the machine where the risk of theft burglary and dam...

Page 164: ...erm parking Follow the instructions as for parking and in addition to that 1 Wash the machine and touch up the paint finish to avoid rusting 2 Check the machine for leakage of oil or water and defects of the attachments and the tracks Replace or repair all damaged or worn parts 3 Treat exposed parts with anti rust agent lubricate the machine thoroughly and apply grease to unpainted surfaces like c...

Page 165: ... at low idling speed for one hour Operate all function cycles when working temperature has been reached Check after long term parking All oil and fluid levels Tension of all screws Air cleaner Hydraulic hoses Seals 164 Operating instructions Parking ...

Page 166: ...r lift the machine with a person in or on the machine WARNING Risk of runaway machine Improper towing methods or faulty equipment could cause the machine to break away from the towing vehicle causing accidents serious injury or death Carefully follow the towing instructions and use only certified towing equipment with adequate load rating NOTE Only use the rear mounted towing hook and the attachin...

Page 167: ...tation for long distance NOTE Select the slow travel mode Slowly drive the machine when towing 3 Keep the tow line angle as small as possible Angle for pulling should not exceed 20 from the horizontal line of tow lope and longitudinal axis of the machine Be careful there should not be also interference with parts of the machine NOTE Keep the cable horizontal straight and parallel to the tracks In ...

Page 168: ...ing to applicable laws and regulations for the country or state in question For further information contact your dealer Weight and dimension Weight and dimension are very useful to estimate the method how the machine is supposed to be transported To comply with the laws and regulations in certain region use the specifications of total weight and dimension See page 317 and 320 Operating instruction...

Page 169: ...brake of the trailer 3 Insert blocks in front of and behind the tyres of trailer 4 Fix loading ramp securely Make sure that the strength width length and thickness of the planks are safe for loading Make sure that the angle of loading ramp is 15 or less 5 Align the machine s tracks to the ramp the dozer blade to the rear to serve as a support in case of an operating error and the attachments to th...

Page 170: ...ating equipment position B and drive forwards until the machine tips on to the ramp 7 Drive down slowly until the machine reaches level ground If the machine is too high to fit in the transporting vehicle it is possible to remove the rotating beacon optional equipment This will reduce the total height of the machine Rotating beacon and satellite antenna folding When transporting the machine fold t...

Page 171: ...bucket cylinder rod does not contact the trailer 3 Never operate any lever other than the travel levers pedals while the machine is on the loading ramp 4 Stop the machine 5 Remove the ignition switch 6 Turn OFF the battery disconnect switch 7 Lock the door and the access covers 8 Secure the machine with tie downs of adequate load rating so that the machine cannot move V1170114 Tie down points 170 ...

Page 172: ...dents Therefore carefully follow the instructions given below 1 Park the machine on flat even and level ground 2 Position dipper arm boom and blade as shown in the illustration 3 Move the control lockout lever up to lock the system securely see page 114 4 Stop the engine check the safety around the machine 5 Close and lock the windshield cab door and engine hood securely 6 As shown in the illustra...

Page 173: ...nt lift the machine a little to check its balance if satisfactory lift it slowly and evenly 8 Maintain good visibility of the machine at all times during the lift And continuously check that the machine is level NOTICE The lifting equipment attached to the lower frame must be vertical when lifting to prevent any damage to the machine 172 Operating instructions Transporting machine ...

Page 174: ...erform many types of work This chapter contains information and instructions regarding the best operating practices to improve efficiency including examples on how the most common attachments are used It is important that the correct technique is used to obtain safe and efficient use of the machine Operating techniques 173 ...

Page 175: ...errain and haul roads in good condition Remove any large rocks or obstacles Fill any ditches and holes Provide equipment and schedule time to maintain terrain conditions Adjust the speed and travel path to minimize the vibration level Drive around obstacles and rough terrain conditions Reduce the speed when it is necessary to go over rough terrain Maintain machines according to the manufacturer s ...

Page 176: ...ces between worksites Back pain associated with whole body vibrations may be caused by other risk factors The following guidelines can be effective to minimize risks of back pains Adjust the seat and controls to achieve good posture Adjust the mirrors to minimize twisted posture Provide breaks to reduce long periods of sitting Avoid jumping down from the machine Minimize repeated handling and lift...

Page 177: ...achine Look after your workmates Make sure that they take care No persons apart from the operator may be present within the working area of the machine Teach them to be on their guard against collapsing banks and rolling stones and to be prepared to dash for safety Changes in stress in a bank immediately prior to a landslip are indicated by small streams of loose material just where the cracks are...

Page 178: ...aulic cylinders must not be operated closer than 10 cm 4 in from their end of stroke positions In case of fire the battery disconnect switch should be turned off Loading on to a vehicle WARNING Risk of crushing Material may fall off when loading a vehicle Make sure that no persons are standing near the vehicle while loading If possible position the machine higher than the vehicle to be loaded Plac...

Page 179: ...achine Work with as much clearance as possible work by slamming the bucket into the ground Do not perform digging by dropping the boom or using the bucket instead of a pick Striking digging or continuous striking can overload the rear of the machine or damage the attachment It is also very dangerous carry out lifting work Basically using this machine as a crane is prohibited However local or natio...

Page 180: ...s before entering the area High voltage overhead power line DANGER Risk of electrocution Working near or making contact with overhead power lines may lead to electrical flashover and electrocution Always keep the minimum clearance from overhead power lines DANGER Risk of electrocution Contact with live parts will cause death or serious injury Never touch live electrical parts High voltage is letha...

Page 181: ...when the machine or its load at any time is closer than the minimum safety distance to a power line is taking a very serious risk 180 Operating techniques Working within dangerous areas ...

Page 182: ...that the roof window may distort how distance is perceived Keep the following in mind to ensure safety when operating Operate the machine slower than normal operation in the vicinity of power lines Consider the long span power line which can sway and reduce the clearance Pay attention when travelling over uneven ground that could cause the machine to lose balance Keep all persons away from the mac...

Page 183: ...y to remove the machine from contact by moving it in the reverse direction from that which caused the contact If the machine cannot be moved away from contact the operator should remain inside cab until the lines have been de energized 182 Operating techniques Working within dangerous areas ...

Page 184: ...trocution Contact with live parts will cause death or serious injury Never touch live electrical parts Loading and unloading is only permissible between the boundary signs The signs may be mounted directly on the power line or on special posts Contact authorised railway personnel to obtain permission to load or unload After any breaks in the work always contact the railway personnel again Operatin...

Page 185: ...mally only the service companies own personnel may expose and arrange provisional suspension of cables Make use of a signal man when you cannot see the actual point where you are working or when the position of the pipe or cable is critical see page 226 The position of the pipe or cable may deviate from the drawing or distances may be incorrectly determined Regard all electrical cables as live 184...

Page 186: ...ary first come down to level ground and make a detour If the machine slides immediately lower the bucket to the ground The machine can turn over due to unbalance Especially do not swing with loaded bucket In unavoidable case pile up earth on the slope and then make the machine level and stable While travelling on a slope keep the angle between boom and arm at 90 110 raise the bucket 20 30 cm from ...

Page 187: ... it 40 50 cm from the ground Working in water and on boggy ground Be very careful when working on boggy ground After working in water or escaping from boggy ground replenish the grease to the attachment pins or the areas affected by the water Check the idler rollers and track drive case oil if contaminated change the oil Escaping from boggy ground In case that one track gets bogged If one track ge...

Page 188: ... above the bottom This operation reveals stones or other obstacles Prod the bottom with the bucket to measure the depth in order to discover any dangerous hollows NOTICE Pay attention to the permissible water depth in order to avoid damage to the machine Permissible working depth in water is the center of upper rollers Do not fully submerge the upper rollers Upon leaving the water make sure all th...

Page 189: ...rate too close to the edge of a steep slope or road bank Take care when working in a place where the machine may tip Dig with the excavator unit over the rear axle with stabiliser blade down In this way the greatest stability is obtained and the machine will be easy to drive away Take care when working on river banks or in other similar places where the ground is soft There is a risk that the mach...

Page 190: ...stem could respond slowly at low temperatures and could cause unexpected machine movements Operate carefully until the hydraulic system has reached operating temperature Read the advice for starting see page 148 Use appropriate fluids for the ambient working temperatures see recommended fluids in specification section The windows must be free from ice and snow before putting the machine to work Wa...

Page 191: ... work if anyone is dangerously close to the demolition object Leave sufficient space in front of the machine for debris to fall to the ground and not hit the cab Fence off the dangerous part of the work site Spray water over the demolition site to prevent harmful dust from spreading Boots with steel reinforcements in the soles and toe caps protective goggles and a hard hat are obvious protective i...

Page 192: ...also covers attachments which are designed and marked by Volvo CE as they are an integrated part of the machine and adapted to the machine Volvo CE is not responsible for attachments manufactured by other companies Such attachments must be CE marked and accompanied by a Declaration of Conformity and user instructions It is the responsibility of the machine owner to make sure that the attachments a...

Page 193: ...d hat and protective gloves when removing attachment pins 1 Lower the bucket lightly on the ground 2 Remove the lock bolt A and nuts B of each pins C and D 3 Remove pins C and D shims F and O rings E then remove the bucket NOTICE Block the removed bucket to stabilise it Keep the pins clean and do not damage the O ring C D A B V1080820 B E F F 192 Operating techniques Attachments ...

Page 194: ...e bucket 2 Put O rings E with shims F at the holes for the dipper arm and bucket 3 Apply grease to the holes 4 Insert pins C 5 Put shims F at the holes for the link and bucket 6 Insert pins D 7 Install lock bolt A and nuts B of each pins NOTE Make sure that there is a clearance of at least 2 mm 0 08 in between nut and lock bolt Lubricate the lock bolt C D A B V1080820 B E F F V1065823 B A 2mm Oper...

Page 195: ...ith a double acting hydraulic cylinder The hook for gripping the attachment is fitted to its piston rod The hydraulic system s pressure acts on the lock cylinder s piston locking the attachment in place against the rear bucket pin This means that the hook adjusts itself and provides gap free locking When checking from the cab if the attachment quick coupler is locked or unlocked slowly curl out th...

Page 196: ...he switch to position 1 to initiate the attachment quick coupler When the attachment quick coupler is initiated the buzzer sounds and the check message and indicator are displayed on the I ECU See page 86 for more information 4 Press the left attachment quick coupler switch for more than 0 7 second to open the attachment quick coupler The switch is returned automatically See page 35 for more infor...

Page 197: ...nd For control instruction see page 100 6 Lower the bucket and curl out to lift up the attachment quick coupler from the bucket 7 Place the bucket flat on the ground and unhook it 8 Press the right attachment quick coupler switch to position 0 to close the attachment quick coupler See page 86 for more information NOTE When the switch is in position 0 the buzzer sounds and the check message for con...

Page 198: ...rm that the attachment quick coupler is locked Then the buzzer sound will be turned off and the check message and indicator will disappear See page 35 for more information 1 V1140835 Attachment quick coupler switch left Operating techniques Attachments connecting and disconnecting 197 ...

Page 199: ...the attachment quick coupler is initiated the buzzer sounds and the check message and indicator are displayed on the I ECU See page 86 for more information 4 Press the left attachment quick coupler switch for more than 0 7 seconds to open the attachment quick coupler The switch is returned automatically See page 35 for more information NOTE When the attachment quick coupler is open the buzzer soun...

Page 200: ... the switch is in position 0 the buzzer sounds and the check message for confirming and indicator are displayed on theI ECU 9 Visually check that the front lock device is fully engaged 10 Lift and curl in the bucket fully towards the dipper arm and hold it there for approximately 5 seconds to ensure that the attachment quick coupler has locked securely to the bucket 11 Press the left attachment qu...

Page 201: ...he front lock device is fully engaged Do not use the machine if the attachment quick coupler is not working Contact a workshop authorized by Volvo if anything is wrong WARNING Risk of crushing If the red warning lamp for open attachment bracket lights up while working the attachment could fall off and cause serious crushing injury or death Stop working with the machine immediately and make sure th...

Page 202: ...achment bracket increases the total length of the dipper arm Be careful when moving the bucket and dipper arm towards the machine there is a risk of damaging the machine NOTICE The attachment bracket is not designed as a lifting device Do not use the front hook or the rotating hook for lifting Only specially designed pin on attachments may be hooked to the attachment bracket NOTICE There is a risk...

Page 203: ... front end is raised slightly 1 Remove linch pin 4 and extract locking pin 3 2 Rotate the locking pin 90 to lock it in extracted position 3 Lower the dipper arm into a position where the attachment bracket connects with front bucket pin 5 4 Lower the attachment bracket towards rear bucket pin 6 Tilt the bucket rearwards bucket in until the hook on the attachment bracket is properly connected to th...

Page 204: ...nd 5 Insert the release bar into the hole at the back of the attachment bracket 6 Pull the release bar to release the attachment bracket from the rear bucket pin WARNING Risk of crushing The bucket is only attached in the front bucket pin The bucket could fall and cause crushing injury Keep a safe distance 7 Place the bucket on the ground 8 Lift the attachment bracket in direction from the bucket ...

Page 205: ...cylinder and dipper arm is set to 90 respectively the working efficiency of each cylinder will be at its maximum Take advantage of this angle to improve the work efficiency The range for effective digging is when the dipper arm is between 30 forward and 45 rearward There may be a little difference according to digging depth Do not use the cylinder up to its stroke end but only within this range NO...

Page 206: ...st and then dig the center area Loading work Position the hauler or truck so as to achieve a small slewing movement and good visibility for the operator to work effectively Also load over the rear side of the dump truck rather than over the side as this makes the operator work easier and increases efficiency V1078415 V1158800 Operating techniques Buckets 205 ...

Page 207: ...il you read and understand operation and maintenance guide NOTE Do not perform any service or maintenance until you read and understand hammer manual NOTICE The standard version of the hammer must not be used under water If water fills the space where the piston strikes the tool a strong pressure wave is generated and the hammer may be damaged NOTICE If the hammer is connected to an attachment bra...

Page 208: ...ck but it is not broken within 1 minute move the hammer to break from the end portion The striking direction of chisel and the direction of hammer body are slightly deviated Therefore adjust the bucket cylinder so that the direction of body and chisel is always the same Press the chisel firmly against the surface so idle striking is avoided V1079564 90 o 90 o V1126877 V1079566 V1126878 V1079568 Op...

Page 209: ...ere is not enough feed force on the tool Realign the tool and press the tool firmly against the material Do not operate the cylinder to its end of stroke leave about 5cm Do not swing the hammer against the rocks concrete and so on Do not move the chisel while it is striking a blow Do not strike horizontally or in an upward direction V1079569 V1117841 V1079571 V1126879 208 Operating techniques Hamm...

Page 210: ... not bend with the chisel to make a hole in the ground Do not hoe the chisel Do not raise the machine by extending the bucket cylinder to maximum V1079573 V1117843 V1126880 Operating techniques Hammer 209 ...

Page 211: ...nnections on the boom 9 Lock the hydraulic couplings NOTE The machine hydraulic oil level must be checked after the hammer has been operated for 2 3 minutes Disconnecting with pivot pins 1 Place the machine on firm and level ground 2 Lower the boom and place the hammer flat on the ground 3 Shut down the engine and turn the key to operating preheating position 1 Release the X1 residual pressure For...

Page 212: ...y unit the central warning lamp lights up and the buzzer sounds unlock position 4 Hook the attachment quick coupler onto the hammer pin 5 Slowly curl in the attachment quick coupler completely towards the hammer 6 Press the switch lock position to lock the hammer in position 7 A message in the display unit will inform you that the attachment is locked to the attachment quick coupler Check that the...

Page 213: ... correct position If you are not sure if the hammer is securely locked to the attachment quick coupler get out and check if the lock wedges have moved in under the hammer pin NOTICE Do not use the machine if the attachment bracket is not working correctly V1114280 Hammer in locked position 212 Operating techniques Hammer ...

Page 214: ...he dipper arm to release the locking mechanism 4 Press the attachment quick coupler switch to open the attachment quick coupler unlock position See page 194 for operating of the attachment quick coupler When the attachment quick coupler is being opened a warning symbol appears on the display unit the central warning lamp lights up and the buzzer sounds unlock position 5 Lower the hammer and curl o...

Page 215: ...d easily X1 double acting option 1 Lower the attachment completely to the ground 2 After turning off the engine turn the ignition switch to operating position See page 148 for operating position 3 Keep the control lockout lever to be at the unlocked position See page 114 4 Push button 2 on the right control lever to select shear function Refer to the page 45 and 86 for selecting X1 shear function ...

Page 216: ...lever to select shear function Refer to the page 45 and 86 for selecting X1 and X3 5 Move proportional switch 3 and 7 from side to side five or six times during 20 30 seconds to release the pressure in X1 and X3 line 6 Connect or disconnect the quick coupler NOTE Disconnected attachment can occur the residual pressure by external load Before connecting the attachment to the machine push the face o...

Page 217: ...humb It is dangerous to leave the thumb and bucket in the air with material inside Before disconnecting or connecting hydraulic hoses the engine must be shut down The ignition key must be switched to travel position and the proportional rollers must be shifted right and left The control levers must be shifted to all directions to relieve trapped pressure To prevent damage on the components and str...

Page 218: ... used disconnect the hydraulic lines and put the quick couplings in their support located on each side of the dipper arm NOTICE Protect the hydraulic connections against dirt because only this will ensure the correct function of hydraulic connections and hydraulic system A B V1078511 Operating techniques Thumb 217 ...

Page 219: ... activated for thumb operation 2 Operate the thumb with the proportional roller on the right lever Roller to the right Open the thumb Roller to the left Close the thumb 3 To return to boom swing mode push the button 3 on the right lever again The proportional roller is now activated for boom swing WARNING Risk of crushing Pressure interruption by mode shifting could cause the load to fall from the...

Page 220: ... after hose rupture When engine is running Lower the boom or arm with the operating levers in the usual way Collect the oil from the ruptured hose in a suitable vessel When engine is stopped The servo hydraulic pressure is maintained by a pressure in accumulator for a few minutes which permits the operator to lower the boom or arm in the usual way with operating levers Do not wait too long to lowe...

Page 221: ...pressure and ensure the ignition switch is in the off position before you perform any service of the hydraulic system 1 Loosen lock nut B a bit and turn adjusting screw A counter clockwise slowly NOTE Before turning the adjusting screw mark its position to facilitate assembling later setting pressure 250 kgf cm The boom will then slowly be lowered to the ground 2 Turn adjusting screw A to its orig...

Page 222: ...Cannot be used on rough ground where there are large obstacles such as boulders or fallen trees C Extremely soft ground boggy ground Use only for ground where A and B are impossible to use Travel in high speed only on flat ground When it is impossible to avoid travelling over obstacles lower the travel speed to approximately half of low speed NOTE Cannot be used on rough ground where there are lar...

Page 223: ...s when travelling on concrete sideways on rocky ground or on stony river beds Be careful not to slip on water snow or sand Especially be careful when loading and unloading the machine Durability of the rubber track may mot be guaranteed with special attachment mounted 3 Driving techniques Driving slowly and turning with a large radius compared to fast small radius turns will extend shoe s life Hig...

Page 224: ...nual and its load charts Specific machine knowledge and training how to properly rig the load Full responsibility for all aspects of the lift Interrupt the lift if not fully confident of a safe lift Select machine with sufficient capacity for the total expected load reach and swing Ideally load should be less than the load listed on the load chart at maximum reach across the undercarriage Know the...

Page 225: ...e local or national regulations that apply for lifting operations For further information contact your dealer Keep the following in mind to ensure the highest level of controllability and safety when lifting Operate on solid flat level ground If ground conditions are unstable for example loose gravel sand or water do not work with loads close to the rated load maximums given on the machine load ch...

Page 226: ...ot the rated load capacity of the machine which varies according to ground conditions reach track position and so on NOTE Only use lifting device recommended by Volvo in order to avoid damage to the machine Contact your dealer for information regarding other lifting device NOTE Hole A and bar B are for boom lifting only Do not use other purpose such as machine lifting 2 Load hooking device on conn...

Page 227: ...n to the respective operators V1065920 V1065921 V1065923 RAISE LOAD VERTICALLY With either forearm vertical forefinger pointing up move hand in small horizontal circles LOWER LOAD VERTICALLY With either arm extended downward forefinger pointing down move hand in small horizontal circles MOVE LOAD IN HORIZONTALLY With either arm extended hand raised and open toward direction of movement move hand i...

Page 228: ...finger pointing horizontally at open hand V1065933 V1065934 V1065935 TURNTHIS FAR TO GO Raise forearm with closed fist indicating inside of turn Move other fist in vertical circle indicating direction of track or wheel rotation THIS FAR TO GO With hands raised and open inward move hands laterally indicating distance to go V1065936 V1065937 V1065938 COUNTER ROTATE Place hand on head indicating side...

Page 229: ...on of track or wheel rotation STOP With either arm extended laterally hand open downward move arm back and forth V1065942 V1065922 EMERGENCY STOP With both arms extended laterally hands open downward wave arms back and forth STOP ENGINE Draw thumb or forefinger across throat 228 Operating techniques Signalling diagram ...

Page 230: ...risks when working with unhealthy material and ways to avoid personal injuries Further safety rules and warnings texts are given within the respective sections WARNING Risk of burns Hot machine parts could cause burns Allow hot machine parts to cool before performing adjustments or service Wear personal protective equipment Safety when servicing 229 ...

Page 231: ...ines and vessels should have the pressure released gradually to avoid risks 6 Allow the machine to cool A suitable position is stated in the description for the different service operations If no particular position is stated the machine should be parked in service position A Service position A Retract the bucket and dipper arm cylinder completely and then lower the boom on the ground V1158751 Ser...

Page 232: ...ised lifting arms these must first be secured Engage the control lever lockout and apply the parking brake if the machine is equipped with one Turn off the engine before opening the rear door and engine cover When the engine is stopped there is a remaining accumulated pressure in the pressurized systems If a system is opened without having first released the pressure liquid under high pressure wil...

Page 233: ...sure than that recommended by the manufacturer Machines which are used within a polluted or in another way insanitary area should be equipped for this kind of work Special safety regulations apply when servicing such a machine When installing two way radio mobile telephone or similar equipment the installation should be carried out in accordance with the manufacturer s instructions in order to eli...

Page 234: ...s must be collected in suitable vessels and steps taken to avoid spillage Used filters must be drained of all liquid before they are passed on as waste Used filters from machines which work in environments with asbestos or other dangerous dust must be placed in the bag supplied with the new filter Batteries contain substances dangerous to the environment and health Used batteries must therefore be...

Page 235: ...running The electrical system may be damaged When welding servicing of electrical system or after finishing work of the day for safety the battery disconnect switch should be turned off V1155519 A B Battery disconnect switch A OFF position B ON position 234 Safety when servicing Before service read ...

Page 236: ...hich shows the exact positions and specifications of respective relays and fuses is provided on the inside of cover see page 312 NOTE If a fuse blows repeatedly in the same position the cause of the fault has to be investigated 1 Loosen screws A and remove cover of the fuse box B 2 Remove the burnt fuse using a fuse holder tool 3 Install a new fuse with same capacity as the old one V1155541 A A B ...

Page 237: ... Hydraulic oil NOTE Hydraulic oil is hazardous to the environment Immediately use barriers to contain spilled oil and follow local regulations concerning hazardous materials NOTICE Only hydraulic oil that is approved by Volvo may be used NOTICE Use the same hydraulic oil that is already in the system The hydraulic system may be damaged if different brands of hydraulic oil are mixed Hydraulic bio o...

Page 238: ...ip that is two hands and one foot or two feet and one hand Always face the machine Always wipe mud and oil off all footboards handrails and your footwear especially clean the windows rear view mirrors and lights Clean your boots and wipe your hands before getting on the machine Do not use hand grip A of the cab door as a support when entering leaving and climbing the machine it is not strong enoug...

Page 239: ...hing compound does not conduct electricity Efficiency class I means that the effective operating time of the extinguisher must not be less than 8 seconds class II at least 11 seconds and grade III at least 15 seconds A hand held fire extinguisher ABE I normally corresponds to a powder content of 4 kg 8 8 lb EN grade 13A89BC standard EN 3 1995 parts 1 2 4 and 5 Fire prevention measures Do not smoke...

Page 240: ...r example saw mill and refuse dumps The risk of spontaneous combustion can be further reduced by installing insulation of the silencer guard It is important that the fire extinguisher is maintained in order to work when it is needed Check that fuel lines hydraulic and brake hoses and electrical cables have not been damaged by chafing or are not in danger of being damaged in that way because of inc...

Page 241: ...ency stop switch 8 Attempt to put out the fire if possible Otherwise move away from the machine and out of the danger zone Actions after fire When handling a machine which has been damaged by fire or been exposed to intense heat the following protective measures must be followed Use thick protective gloves made of rubber and wear goggles Never touch burnt components with your bare hands in order t...

Page 242: ...ment and protective goggles Paint remover or other chemicals use a portable air extractor respiratory protective equipment and protective gloves Grinding machine use a portable air extractor respiratory protective equipment and protective gloves and goggles Never burn painted parts after they have been discarded They should be disposed of by a licensed disposal plant Heated rubber and plastics Pol...

Page 243: ... machine which has been damaged by fire or been exposed to intense heat the following measures should be taken Use thick rubber gloves and wear protective goggles Discard gloves rags and other items that have been in contact with heated fluoro carbon rubber after first having washed these items in lime water a solution of calcium hydroxide that is slaked lime in water 242 Safety when servicing Han...

Page 244: ...d with Hydrofluoric Acid Burn Jelly or similar before contacting a medical doctor Crystalline silica quartz dust WARNING Risk of hazardous inhalation Working in environments containing dangerous dust can lead to serious health problems Wear personal protective equipment when working in dusty environments Crystalline silica is a basis component of sand and granite Therefore many activities at const...

Page 245: ...ols rings and watch straps do not come into contact with the battery pole studs Make sure the protections are always installed over the battery pole studs Do not tilt a battery in any direction Battery electrolyte may leak out Do not connect a discharged battery in series with a fully charged battery Risk for explosion When removing a battery disconnect the ground cable first and when installing c...

Page 246: ... air conditioning system Wear safety goggles chemical resistant gloves e g neoprene or butyl rubber and appropriate personal protective equipment to protect bare skin when there is a risk of contact with refrigerant Actions in case of exposure Eye contact Rinse with warm water and apply a light bandage Seek medical attention immediately Limited skin contact Rinse with warm water and apply a light ...

Page 247: ...nd to check for leaks Tighten all connections Consult your Volvo Construction Equipment dealer for the recommended tightening torque If any of the following conditions are found replace the parts Consult your Volvo Construction Equipment dealer Connections and end fittings are damaged leaking deformed or aged Outer coverings are chafed or cut Strengthening wires are exposed Outer coverings are bal...

Page 248: ...ch completed service by a qualified service technician the service history should be filled in see page 334 Service history is a valuable document which is referred to when selling the machine Arrival Inspection Before the machine leaves the factory it is tested and adjusted The dealer or distributor must also carry out arrival inspections according to the applicable form Delivery Inspection Befor...

Page 249: ...ine shall be maintained according to the service program established by Volvo The service program is continuous with fixed intervals The operating time between intervals only applies if the machine is used in normal environment and operating conditions Ask your Volvo dealer what is right for your specific machine 248 Maintenance ...

Page 250: ...risk of forgetting greasing points Lubrication has two main purposes To supply grease to the bearing in order to reduce wear between the pin and the bearing To replace old and dirty grease The grease stored inside the outer seal collects dirt and water and prevents them from penetrating into the bearing NOTICE Wipe off grease nipples and grease gun before greasing so that dirt and sand are not int...

Page 251: ...oil check 5 Track drive gear oil check 6 Track drive gear oil change 7 Hydraulic oil 8 Hydraulic oil level 9 Hydraulic oil filter 10 Hydraulic tank air breather filter 11 Fuel filter 12 Water separator 13 Engine coolant 14 Engine coolant filter 15 Engine coolant level 16 Engine oil level 17 Engine oil filter 18 Operator manual 19 Air cleaner filter 250 Maintenance Lubrication and service chart ...

Page 252: ...Lubrication and service chart V1155518 1 4 5 6 7 8 10 11 12 17 16 18 16 16 13 14 15 16 16 16 9 2 3 Maintenance Lubrication and service chart 251 ...

Page 253: ...r fluid level 262 Lubricate to attachments and dozer blade unit 16 263 Check the belt tension for air conditioning Workshop job 2 Drain the water from the air compressor tank 262 Every 50 hours Item Page Check the track tension 15 265 Every 250 hours after carrying out Daily and 50 hours services Item Page Check the oil level of track drive unit 13 268 Lubricate the swing gear bearing 17 268 Clean...

Page 254: ...11 Workshop job 2 Change the water separator filter element 10 Workshop job 2 Check the belt tension for alternator Workshop job 2 Change the hydraulic oil return filter 3 4 Workshop job 2 Check the fuel hoses Workshop job 2 Check the radiator hoses Workshop job 2 Change the air filter of the air compressor 270 1 Or when required 2 Contact a workshop authorized by Volvo 3 First change 250 hours Ma...

Page 255: ...raulic servo filter 2 12 Workshop job 3 Check the engine valve clearance Workshop job 3 Change the oil of track drive unit 2 14 Workshop job 3 Clean the air breather filter on hydraulic tank 1 Workshop job 3 Check the EGR piping Workshop job 3 Check the exhaust manifold Workshop job 3 1 At least once a year 2 First change 250 hours 3 Contact a workshop authorized by Volvo 254 Maintenance Lubricati...

Page 256: ...es and hoses Workshop job 1 Check the crankcase ventilation separator rubber hoses Workshop job 1 Check the charge air pressure sensor hose Workshop job 1 Check the EGR cooler hose Workshop job 1 Check the water hose Workshop job 1 Check the lubricant hose Workshop job 1 1 Contact a workshop authorized by Volvo Maintenance Lubrication and service chart 255 ...

Page 257: ...e primary filter is replaced 1 286 Check the coolant content 2 274 Change the air ventilation filter on fuel tank Workshop job 3 Change the hydraulic oil mineral oil 2 Workshop job 3 Clean the suction strainer of hydraulic tank Workshop job 3 Every 3000 hours after carrying out Daily 50 250 500 1000 1500 and 2000 hours services Item Page Clean the diesel particulate filter Workshop job 3 Check the...

Page 258: ... Daily 50 250 500 1000 1500 2000 3000 and 4000 hours services Item Page Change the hydraulic oil bio oil and long life hydraulic oil Workshop job 1 Every 6000 hours after carrying out Daily 50 250 500 1000 1500 2000 3000 4000 and 5000 hours services Item Page Change the coolant 2 6 Workshop job 1 1 Contact a workshop authorized by Volvo 2 Or at least every 4 years Maintenance Lubrication and servi...

Page 259: ...ion tank and cause severe burns Before removing the expansion tank pressure cap Shut down the engine Allow the engine to cool Turn the pressure cap slowly to release any pressure 1 Position the machine on even firm and level ground 2 Open the rear engine hood 3 Check the coolant level on expansion tank B If the coolant level is lower than MIN marking on the tank top up the coolant through radiator...

Page 260: ...and check the level If the level is normal clean the dismantled parts and install them NOTICE Use the same hydraulic oil that is already in the system The hydraulic system may be damaged if different brands of hydraulic oil are mixed 6 If the level is high Place a suitable sized container under the hydraulic tank Remove protecting cap C and attach drain hose D which is the same hose as that used f...

Page 261: ...oil level when the machine has cooled down at least 30 minutes after turning off the engine 1 Position the machine on even firm and level ground 2 Open the engine hood 3 Pull out dipstick A and wipe it with a clean cloth 4 Push it in and pull it out again 5 If the oil level is between C and D it is normal If the oil level is below D refill the oil to proper level through filler port B For the reco...

Page 262: ... torque below Steel shoe 22 1 kgf m 216 9 8 N m 159 7 2 lbf ft Rubber shoe 22 1 kgf m 216 9 8 N m 159 7 2 lbf ft NOTICE It is very important that loose track shoe screws and nuts are removed fully and that the threads are cleaned Clean the track shoes before they are installed and the screws tightened 3 After tightening check whether the nut and the shoe are in full contact with the mating surface...

Page 263: ...ecommendations as regards the ambient temperature Air compressor air tank water draining Drain the water from the air compressor tank daily 1 Open drain valve B under air compressor tank A and drain the water from the tank 2 Close the drain valve V1155520 Washer reservoir V1155543 A B A Air compressor tank B Drain valve 262 Maintenance Maintenance service every 10 hours ...

Page 264: ...ter greasing clean off the superfluous grease Immediately after working under severe operating conditions where mud water and abrasive material may enter the bearings grease the submerged parts such as the bucket pins to remove the old grease regardless of the grease interval For grease specification see page 298 3 1 2 2 4 V1155528 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Maintenance Maintenance servi...

Page 265: ...bucket 1 point 8 Pin between arm and link 1 point 9 Bucket cylinder mounting pin 1 point 10 Arm cylinder rod end pin 1 point 11 Pin between boom and arm 1 point 12 Arm cylinder mounting pin 1 point 13 Boom cylinder rod end pin 1 point 14 Boom cylinder mounting pin 1 point 15 Boom mounting pin 1 point 16 Dozer blade mounting pin 2 points 17 Dozer blade cylinder rod end pin 1 point 18 Dozer blade cy...

Page 266: ... and bushings varies with the working condition or the characteristics of soil Check the track tension often and keep it to the specified value When working in wet sand or clay it sticks to and packs between moving undercarriage components This can prevent mating parts from properly engaging each other which cause interference and high loads Due to abrasive particles in the material it significant...

Page 267: ...the bottom of track frame and the upper surface of track shoe 4 Adjust the track tension according to the soil characteristics For more information see page 287 Recommended track tension is as below Working condition Clearance L mm in Steel shoe General soil 130 140 5 1 5 5 Rocky ground 120 130 4 7 5 1 Moderate soil like gravel sand snow and so on 140 150 5 5 5 9 Rubber shoe Rubber track type 63 7...

Page 268: ... damaged Too much oil makes the oil foaming and cause the track drive unit to overheat WARNING Risk of burns Hot liquids and machine parts can cause burns Allow the machine to cool before beginning any service WARNING Risk of high pressure injection Residual pressure in the hydraulic system could lead to oil under high pressure jetting out and cause serious injury even if the engine has not been r...

Page 269: ...swing gear every 250 hours 1 Park the machine on level ground and lower the bucket to the ground 2 Move the control lockout lever up to lock the system securely and stop the engine See page 114 3 Clean the grease nipples 4 Fill the grease at grease nipple A using a hand or power grease gun 5 Grease the swing ring bearing four times After each time swing the superstructure 90 6 Take care not to sup...

Page 270: ... Replace the air conditioning filter every 1000 hours 1 Open the cab door 2 Take out the air conditioning filter and clean it with compressed air 3 Insert the air conditioning filter into the slot and make sure that the filter is locked fully NOTE Clean the filter with compressed air with a maximum pressure of 0 2 Mpa 30 psi NOTE If the filter is damaged or heavily contaminated replace it with a n...

Page 271: ...clean the condenser core The refrigerant can overheat When cleaning with water protect the electrical components 1 Position the machine on even firm and level ground 2 Open the rear engine hood 3 Clean any mud dust or leaves attached to the radiator fins and oil cooler fins with compressed air or steam 4 Check the rubber hose for wear and cracks If damaged replace it Check the hose clamp for loose...

Page 272: ...lower the bucket to the ground 2 Move the control lockout lever up to lock the system securely and stop the engine See page 114 3 Clean the grease nipples 4 Fill the grease at grease nipple A using a hand or power grease gun 5 Take care not to supply excessive mount of grease 6 After greasing clean off the superfluous grease completely If the grease is contaminated or discoloured with water contac...

Page 273: ...es greasing Grease the cab door hinges every 1000 hours Engine air cleaner primary filter replacing See page 284 Air conditioning filter cleaning and replacing See page 268 V1155524 A A Grease points 272 Maintenance Maintenance service every 1000 hours ...

Page 274: ...Maintenance service every 2000 hours Engine air cleaner secondary filter replacing See page 286 Maintenance Maintenance service every 2000 hours 273 ...

Page 275: ...anging the coolant Volvo Coolant VCS is yellow and a decal by the filling point shows that the system is filled with this coolant see picture NOTICE Volvo Coolant VCS must never be mixed with any other coolant or corrosion protection to avoid damage to the engine The cooling system capacity when changing see page 309 If concentrated Volvo Coolant VCS and clean water see page 301 is used the table ...

Page 276: ...entrated coolant NOTICE In order to avoid damage to engine and cooling system different brands of coolant or corrosion protection must not be mixed Freeze protection down to Content of concentrated coolant 25 C 13 F 40 35 C 31 F 50 46 C 51 F 60 Maintenance Maintenance service every 2000 hours 275 ...

Page 277: ...y heater before filling fuel 1 Carefully clean around the filler cap on the fuel tank before removing it 2 Open the fuel filler cap A and fill the fuel in the tank 3 Check the fuel level on the I ECU See page 38 Avoid spilling the fuel when filling which attracts dirt If fuel is spilled clean it up immediately During the cold season fill up the fuel tank to prevent water condensing in the tank For...

Page 278: ...n start button C The pump will run as long as the tank is not full At any time during the refuelling or when the drum has been emptied the pump may be stopped by pressing the red button D The pump will automatically stop when the fuel level sensor is actuated The pump cannot be restarted until the fuel from the tank is used 6 Fold the hose and reinstall the strainer cover 7 Close the front cover 8...

Page 279: ...he check screen for water in fuel pops up on the I ECU 1 Place a suitable sized container under drain hose C 2 Open the drain valve B and drain the sediment into a container NOTICE Take care of filters oils and liquids in an environmentally safe way 3 Close the drain valve B V1155535 A B C A Water separator B Drain valve C Drain hose 278 Maintenance Maintenance service when required ...

Page 280: ...tery electrolyte contains corrosive sulphuric acid which could cause severe chemical burns If electrolyte spilled on your bare skin remove it immediately and wash the affected area with soap and plenty of water If it gets into your eyes or any other sensitive body part rinse with plenty of water and seek immediate medical attention Always turn off the charging current before the charging lead clip...

Page 281: ...close to the welding point as possible and make sure that the current does not pass across a bearing 5 Ventilate well specially if the welding is performed in a confined space 6 Remove all paint from an area of at least 10 cm 4 in around the welding point WARNING Risk of toxin inhalation Burning of painted plastic or rubber parts produces gases that could damage respiratory tracts Never burn paint...

Page 282: ...cleaned regularly from of soil and clay NOTE Daily clean the areas on the machine where dust chips and similar may collect in order to minimise the risk of fire see page 238 Place the machine in a place intended for cleaning Follow the instructions supplied with the car care product The water temperature must not exceed 80 C 176 F If high pressure wash is used keep a distance of at least 40 cm 16 ...

Page 283: ...e Machines which are used in corrosive environment suffer more from rust than others As a preventive measure it is recommended that the paint finish should be maintained every sixth months At first clean the machine Apply Dinol 77B or corresponding transparent waxy anti rust agent at a thickness of 70 80 µ A protective layer of underseal Dinitrol 447 or corresponding may be applied under the mudgu...

Page 284: ...d to fire hazards for example wood processing woodchip handling or grain handling and animal feed industries require daily attention and cleaning of the engine compartment and surrounding areas When operating in other environments inspection and cleaning is required at least once a week Loose material is removed with for example compressed air Cleaning should preferably be carried out at the end o...

Page 285: ...cleaner to the engine induction manifold do not leak Engine air cleaner primary filter cleaning and replacing Clean the filter when the check screen for engine air filter clog pops up on the I ECU The filter may be cleaned at the most five times Thereafter or after maximum 1 year the filter should be replaced Also replace the filter if it is damaged NOTE Do not clean the filter if the check screen...

Page 286: ...mary filter and the cover 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 Do not hold the nozzle closer than 3 5 cm 1 2 in 2 Blow the filter from the inside along the folds 3 Check the filter with the aid of a lamp 4 If there is the smallest hole scratch crack or other damage the filter must be discar...

Page 287: ... to be replaced 1 The secondary filter should be removed carefully and with precision so that no impurities enter the engine 2 Carefully check that the new secondary filter is correctly installed NOTICE Take care of filters oils and liquids in an environmentally safe way Engine air cleaner cover cleaning The cover for aircleaner should be cleaned when the primary filter is cleaned 1 Remove the cov...

Page 288: ...t again Loosening track tension increasing slack 1 Loosen the valve A gradually to drain the grease but not more than one turn If the grease does not drained smoothly move the machine forward and rearward NOTICE Risk of environmental pollution The grease in the track adjustment cylinder is under high pressure and large quantities of grease will be quickly released if the valve is loosened too much...

Page 289: ...fore replacing the bucket tooth For side pin locking system 1 Lower the bucket horizontally and place it on a block 2 Move the control lockout lever up to lock the system securely and stop the engine 3 Drive out the pin B using a hammer and punch Be careful not to damage the locking washer C Use a round bar with a smaller diameter than the pin as a punch 4 Clean the surface of adapter D and insert...

Page 290: ...tate replacement of teeth The tool are available in different sizes depending on tooth size Contact your dealer for further information Removing tooth 1 Lower the bucket horizontally on a block and angle it slightly upward 2 Move the control lockout lever up to lock the system securely and stop the engine 3 Clean the opening for tooth adapter locking device 4 Knock out the locking device with a ha...

Page 291: ...ts forward 5 Knock down the locking device with a hammer until it is level with the upper part of the tooth adapter 6 Knock down the locking device further with a hammer and the tool or other suitable drift until the upper part is just below the scored line in the hole NOTE Replace the steel pin in connection with replacement of tooth adapter V1066080 A B Locking device A Steel pin B Lock retainer...

Page 292: ...ade on the block 2 Remove the screws C and cutting edges B 3 Clean the dozer blade surface and removed parts 4 Turn the cutting edges upside down if those edges are not worn If both sides of the cutting edges are worn replace the parts with new one 5 Install the cutting edges and screws Tightening torque for cutting edges screws 26 7 2 7 kg m 6 After a few hours of operation tighten the screws C t...

Page 293: ...n working on the hydraulic system Remove hydraulic system pressure 1 Place attachment on the ground and shut down engine 2 After engine is shut down turn ignition switch to operating position Do not start engine 3 Keep the control lockout lever down unlocked position and move all control levers and pedals to release main system pressure from all lines 4 Turn ignition switch to OFF position remove ...

Page 294: ...ops the accumulator allows the attachment to move by its own weight After releasing the pressure in accumulator move the control lockout lever up to lock the system securely see page 114 Accumulator emergency operation 1 Stop the engine by turning the ignition switch to stop position 2 Turn the ignition switch to operating preheating position 3 Move the control lockout lever down to unlock the sys...

Page 295: ...g position 4 Move the control lockout lever down to unlock the system 5 To release the pressure in the control circuits and accumulator move the operating levers and pedals forward rearward and left right to their respective end positions 6 Turn the ignition switch to stop position 7 Move the control lockout lever up to lock the system securely 294 Maintenance Maintenance service when required ...

Page 296: ...y deterioration such as deformation or cracking replace the clamps at the same as the hoses When replacing the hoses always replace the O rings gaskets and other related parts at the same time The replacements should be carried out by a qualified service technician Inspection interval Item Daily Fuel hydraulic hoses leakage of connections and end fittings Monthly Fuel hydraulic hoses leakage damag...

Page 297: ... from corrosion It is highly recommended to use dielectric grease in all harness connecting points for better sealing and to prevent corrosion Freezing weather After working fill up the fuel tank to prevent water from condensing in the tank 276 Use the recommended lubricants 298 Fully charge the batteries regularly electrolyte may freeze Ventilate well especially when the batteries are charged in ...

Page 298: ...ter service intervals 270 Clean the areas on the machine where dust chips and similar may collect at shorter service intervals in order to minimize the risk of fire 281 Pay attention to and clean the engine compartment and surrounding areas regularly 283 Rocky ground Use a suitable track for the ground conditions If in doubt contact your closest Volvo dealer for proper advice 221 Use a suitable at...

Page 299: ...ality for example biologically degradable oil is to be used System Oil grade Recommended viscosity at varying ambient temperature Engine Engine oil see page 300 C F 30 22 10 14 0 32 10 50 20 68 30 86 40 104 50 122 20 4 SAE 10W 30 SAE 15W 40 SAE 10W 40 SAE 5W 30 SAE 5W 40 Track gearbox Gear oil with EP additive API GL4 or GL5 C F 30 22 10 14 0 32 10 50 20 68 30 86 40 104 50 122 20 4 SAE 90 SAE 140 ...

Page 300: ...20 68 30 86 40 104 50 122 20 4 ASTM D975 No 2 ASTM D975 No 1 Cooling system Volvo Coolant VCS Volvo Coolant VCS should be used only see page 301 Air conditioner system Refrigerant HFC R134a Installed at factory Extreme Pressure If the machine is filled with Volvo Biodegradable hydraulic oil this oil must also be used when filing and changing The mineral oil content in bio oil should not exceed 2 w...

Page 301: ...nt in the fuel ppm 10000 ppm 1 15 15 500 500 3000 3000 5000 5000 Oil change interval Volvo Engine Oil VDS 4 5 500 hours Not applicable Volvo Engine Oil VDS 4 ACEA E9 250 hours Not applicable API CJ 4 or CK 4 ACEA European Automobile Manufacturers Association API American Petroleum Institute 300 Specifications Recommended lubricants ...

Page 302: ... The concentrated coolant must not be mixed with water that contains a high degree of lime hard water salt or metals The clean water for the cooling system must also meet the following requirements Description Value Total number of solid particles 340 ppm Total hardness 9 5 dH Chloride 40 ppm Sulphate 100 ppm pH value 5 5 9 Silica 20 mg SiO2 litre Iron 0 10 mg Fe litre Manganese 0 05 mg Mn litre E...

Page 303: ... completion machine for other conditions like engine starting performance In this range a warming up period is needed to obtain proper performance C Ambient temperature range to operate machine under special conditions not a recommendation for general use conditions Additional recommendation for severe cold areas A field solution for severe cold condition of ambient temperature between 40 C and 20...

Page 304: ...HELL Retinax HDX2 Alvania HDX2 Retinax EP2 Alvania EP2 TOTAL Multis MS2 Multis EP2 CASTROL Pyro LM Pyroplex Red Alternatives are not recommended when the ambient temperature is above 40 C Mixability of types of grease with different additives Mixability of types of grease with additives Lithium Calcium Lithium complex Calcium complex Aluminiu m complex Clay Lithium Calcium Lithium complex Calcium ...

Page 305: ... e g rape seed methyl ester RME fuel which are offered on certain markets both as pure products and as mixed into the diesel fuel Volvo Construction Equipment accepts a maximum intermix of 7 bio diesel fuel in the diesel fuel ready mixed from the oil companies A higher intermix than 7 of bio diesel fuel may cause Increased emission by nitrogen oxide thereby not meeting legal requirements Shorter s...

Page 306: ...e resources such as vegetable oils or animal fat Biodiesel that has been chemically processed into fatty acid methyl ester FAME can be blended with distillate diesel fuel and used in some diesel engines Unblended biodiesel is referred to as B100 because it is 100 biodiesel Rapeseed methyl ester RME is the most common type of FAME used in Europe Soy methyl ester SME and sunflower oil methyl ester S...

Page 307: ...EU Stage IIIA US Tier 3 D9 D16 Up to B20 EU Stage IIIB US Tier 4 interim EU Stage IV US Tier 4 final D11 D16 Up to B10 EU Stage IIIB US Tier 4 interim equipped with High Sulphur Fuel Conversion Kit only available in unregulated markets EU Stage IV US Tier 4 final equipped with High Sulphur Fuel Conversion Kit only available in unregulated markets Up to B20 As Tier 2 and Tier 3 emissions regulation...

Page 308: ...t fuel filter replacements Start with new fuel filters when using biodiesel for the first time Biodiesel is aggressive to some materials used in fuel system components Inspect seals hoses rubber and plastic components every 10 hours Repair or replace any components that are damaged softened or leaking Clean biodiesel from painted surfaces immediately to prevent paint damage Biodiesel is more sensi...

Page 309: ...es below 0 C 32 F and may cause problems starting the engine Use a fuel heater or park machines in a heated building if possible Effects of biodiesel on emissions compliance Engines are certified to comply with U S EPA California and EU emissions standards based upon the use of test fuels with specifications established by these regulatory agencies Alternative fuels including biodiesel that are no...

Page 310: ... filter 11 litres 2 9 US gal Coolant 10 litres 2 6 US gal Hydraulic tank 76 litres 20 US gal Hydraulic system total 120 litres 32 US gal Track gearbox each 0 8 litres 0 2 US gal Fuel tank 105 litres 27 7 US gal Swing ring gear 6 litres 1 6 US gal 5 4 kg 11 9 lb Specifications Service capacities and change intervals 309 ...

Page 311: ...2 years Water separator filter element 500 Air ventilation filter fuel tank 2000 Crankcase ventilation separator element 1500 Air filter of air compressor 500 a First change 250 hours Oil and liquid changes Oil liquid Hours Engine oil 500 Track drive unit oil 1000 a Coolant 6000 Hydraulic oil mineral oil 2000 Hydraulic oil bio oil and long life hydraulic oil 5000 a First change 250 hours When usin...

Page 312: ... 60 HP Power output at 2200 rpm ISO 9249 SAE J1349 Net 42 7 kW 59 PS 58 HP Maximum torque 221 6 Nm 23 kgf m 163 0 lbf ft at 1500 rpm Cylinder bore 87 mm 3 42 inch Stroke 110 mm 4 33 inch Displacement 2 615 litres 160 cu in Compression ratio 16 8 1 Injection order 1 3 4 2 Idling speed low 1000 rpm Idling speed high 2350 rpm Specifications Engine 311 ...

Page 313: ...y Main RE3611 Relay Horn RE2703 Relay Ignition switch RE3502 Relay Work light counterweight RE3507 Relay Work light front RE3601 Relay Wiper RE3602 Relay Washer RE9110 Relay Dozer blade control down RE3508 Relay Work light cab RE3528 Relay Work light boom RE9119 Relay Safety RE9111 Relay Dozer blade control up 312 Specifications Electrical system ...

Page 314: ...Spare FU10 10A WECU Telematics ECU Keypad WIF FU11 10A Attachment quick coupler FU12 20A Spare FU13 15A Spare FU14 10A CCM Climate Control Module FU15 20A Seat heater Power outlet 12V FU16 25A Fuel filler pump FU17 10A Audio Microphone FU18 15A V ECU Vehicle Electronic Control Unit FU19 20A Air conditioner FU20 10A Ignition switch FU21 10A Spare FU22 20A Water separator heater FU23 10A Microphone ...

Page 315: ...ied out according to ISO 2631 1 1997 and ISO 8041 1990 Excavating mining quarry and hydraulic breaker application is less than 0 5 m s A 8 Transfer movement traveling is 0 5 0 9 m s A 8 NOTE These whole body vibration values was determined at particular operating and terrain conditions and it is therefore not representative for the various conditions in accordance with the intended use of the mach...

Page 316: ...l valve Main relief pressure Boom Dipper arm Bucket Travel X1 Boom swing 22 5 0 25 MPa 229 2 6 kgf cm 3263 36 3 psi at 60 l min 16 gpm Swing Dozer blade 21 6 0 5 MPa 220 5 1 kgf cm 3133 72 5 psi at 35 l min 9 2 gpm Port relief pressure Boom small chamber Dipper arm Bucket X1 Boom swing 25 5 0 5 MPa 260 5 1 kgf cm 3699 72 5 psi Boom large chamber 26 0 0 5 MPa 265 5 1 kgf cm 3771 72 5 psi Specificat...

Page 317: ...a Right and left 1 88 Nm 0 19 kgf m 1 39 lbf ft Track motor Type Variable displacement axial piston motor with mechanical brake Relief valve setting pressure 22 6 MPa 230 kgf cm 3270 psi Brake type Multi disc spring applied hydraulic released Track gearbox Type 2 stage planetary Swing motor Type Fixed displacement axial piston motor with mechanical brake Relief valve setting pressure 19 6 MPa 200 ...

Page 318: ...Machine weights Machine weights be changed according to variable machine options See page 318 for more information Specifications Machine weights 317 ...

Page 319: ... 27 1 0 28 4 Rubber track 400 16 5853 12910 33 0 0 34 5 Rubber pad 400 16 5950 13120 33 3 0 34 5 Boom m ft in 3 0 m 9 10 Dipper arm m ft in 1 9 m 6 3 Bucket l kg lb 176 l 163 kg 360 lb Counterweight kg lb 440 kg 970 lb Description Shoe width mm in Operating weight kg lb Ground pressure kPa kgf cm2 psi Steel track 380 15 5964 13150 35 4 0 36 5 500 20 6066 13380 27 4 0 28 4 Rubber track 400 16 5913 ...

Page 320: ...0 0 28 4 Rubber track 400 16 5819 12830 32 8 0 33 5 Rubber pad 400 16 5916 13040 33 1 0 34 5 Boom m ft in 3 0 m 9 10 Dipper arm m ft in 1 9 m 6 3 Bucket l kg lb 142 l 129 kg 280 lb Counterweight kg lb 440 kg 970 lb Description Shoe width mm in Operating weight kg lb Ground pressure kPa kgf cm2 psi Steel track 380 15 5930 13080 35 2 0 36 5 500 20 6032 13300 27 2 0 28 4 Rubber track 400 16 5879 1296...

Page 321: ...ght of cab 2584 8 6 2584 8 6 D Tail swing radius 1650 5 5 1650 5 5 E Overall height of engine hood 1630 5 4 1630 5 4 F Counterweight clearance 671 2 2 671 2 2 G Tumbler length 1990 6 6 1990 6 6 H Track length 2500 8 2 2500 8 2 I Track gauge 1520 5 0 1520 5 0 J Shoe width 380 1 3 380 1 3 K Minimum ground clearance 350 1 2 350 1 2 L Overall length 5800 19 0 5865 19 3 M Overall height of boom 1854 6 ...

Page 322: ...ger dozer blade lifting height 405 1 3 405 1 3 Q Standard dozer blade digging depth Q Angle dozer blade digging depth 476 1 6 682 2 2 476 1 6 682 2 2 Q Zero offset longer dozer blade digging depth 635 2 2 635 2 2 R Boom swing distance left 755 2 6 755 2 6 S Boom swing distance right 684 2 3 684 2 3 T Boom swing angle left deg 70 70 U Boom swing angle right 60 60 V Angle dozer blade to left 25 25 W...

Page 323: ...g reach on ground 6040 19 10 6330 20 9 C Maximum digging depth 3765 12 4 4065 13 4 D Maximum cutting height 5765 18 11 5950 19 6 E Maximum dumping height 4085 13 5 4270 14 0 F Maximum vertical wall digging depth 2995 9 10 3280 10 9 G Minimum front swing radius 2465 8 1 2470 8 1 H Maximum digging depth level the ground of 2 44 m 8 3380 11 1 3720 12 2 322 Specifications Working ranges ...

Page 324: ...5970 19 7 6260 20 6 C Maximum digging depth 3695 12 1 3995 13 1 D Maximum cutting height 5695 18 8 5885 19 4 E Maximum dumping height 4150 13 7 4340 14 3 F Maximum vertical wall digging depth 2625 8 7 2900 9 6 G Minimum front swing radius 2465 8 1 2470 8 1 H Maximum digging depth level the ground of 2 44 m 8 3295 10 10 3640 11 11 Machine with direct fit bucket Specifications Working ranges 323 ...

Page 325: ...cket 1 5 t m l kg 300 250 275 200 GP bucket 1 8 t m 275 200 250 200 NOTE Bucket size based on ISO 7451 heaped material with a 1 1 angle of repose NOTE Maximum permitted sizes are for reference only and are not necessarily available from the factory NOTE Bucket widths are less than bucket s tip radius 324 Specifications Recommended bucket sizes ...

Page 326: ...ISO 6015 kN kgf lbf 27 9 2843 6270 24 7 2520 5560 Rotation angle bucket deg 174 7 174 7 For North America Description Unit Boom 3 0 m 9 10 Dipper arm 1 6 m 5 3 1 9 m 6 3 Breakout force bucket SAE J1179 kN kgf lbf 37 7 3843 8470 37 7 3843 8470 ISO 6015 kN kgf lbf 43 3 4410 9720 43 3 4410 9720 Tearout force dipper arm SAE J1179 kN kgf lbf 28 2 2875 6340 25 0 2553 5630 ISO 6015 kN kgf lbf 28 8 2934 6...

Page 327: ... track Counterweight 440 kg Dozer blade Down 4 m 1450 1180 1420 1020 4 32 3 m 1510 1160 1320 820 4 93 2 m 2320 1720 1730 1110 1470 790 1330 730 5 23 1 m 2910 1590 1960 1060 1540 770 1400 700 5 3 0 m 1360 1360 3050 1530 2060 1020 1520 750 1450 720 5 13 1 m 2430 2430 3230 2990 2790 1530 1930 1010 1440 810 4 72 2 m 3140 3040 2130 1560 1340 1060 3 95 Boom 3 0 m Dipper arm 1 6 m Shoe 380 mm Steel track...

Page 328: ...rweight 440 kg Dozer blade Down 4 m 1450 1190 1420 1040 4 32 3 m 1510 1170 1320 830 4 93 2 m 2320 1740 1730 1130 1470 800 1330 740 5 23 1 m 2910 1610 1960 1070 1540 780 1400 710 5 3 0 m 1360 1360 3050 1550 2060 1040 1520 760 1450 730 5 13 1 m 2430 2430 3230 3020 2790 1550 1930 1030 1440 820 4 72 2 m 3140 3080 2130 1570 1340 1070 3 95 Boom 3 0 m Dipper arm 1 6 m Shoe 400 mm Rubber pad Counterweight...

Page 329: ...eight 440 kg Dozer blade Down 5 m 1380 1320 3 71 4 m 1280 1190 1160 900 4 68 3 m 1360 1170 1310 800 1090 740 5 24 2 m 2070 1740 1600 1110 1380 790 1090 660 5 52 1 m 2740 1600 1870 1050 1480 760 1140 640 5 58 0 m 1510 1510 3020 1520 2030 1010 1530 740 1270 650 5 43 1 m 2060 2060 2880 2880 2890 1500 1980 990 1380 730 1350 720 5 05 2 m 3400 3400 3700 2970 2370 1510 1590 1000 1300 900 4 35 3 m 1690 16...

Page 330: ...rweight 440 kg Dozer blade Down 5 m 1380 1330 3 71 4 m 1280 1200 1160 910 4 68 3 m 1360 1180 1310 820 1090 750 5 24 2 m 2070 1760 1600 1130 1380 800 1090 670 5 52 1 m 2740 1620 1870 1070 1480 770 1140 650 5 58 0 m 1510 1510 3020 1540 2030 1020 1530 750 1270 660 5 43 1 m 2060 2060 2880 2880 2890 1520 1980 1000 1380 740 1350 730 5 05 2 m 3400 3400 3700 3010 2370 1530 1590 1020 1300 910 4 35 3 m 1690...

Page 331: ...e 380 mm 15 Steel track Counterweight 440 kg 970 Ib Dozer blade Down 13 2 ft 3210 2570 3140 2280 14 13 9 9 ft 3310 2540 2920 1820 16 14 6 6 ft 5070 3760 3790 2440 3230 1730 2920 1620 17 16 3 3 ft 6360 3490 4300 2320 3370 1680 3090 1560 17 39 0 ft 3060 3060 6670 3360 4520 2240 3330 1650 3200 1600 16 86 3 3 ft 5390 5390 7200 6520 6120 3340 4220 2220 3180 1800 15 49 6 6 ft 6860 6650 4650 3410 2960 23...

Page 332: ...16 Rubber pad Counterweight 440 kg 970 Ib Dozer blade Down 13 2 ft 3210 2600 3140 2310 14 13 9 9 ft 3310 2570 2920 1840 16 14 6 6 ft 5070 3800 3790 2470 3230 1750 2920 1640 17 16 3 3 ft 6360 3530 4300 2350 3370 1700 3090 1580 17 39 0 ft 3060 3060 6670 3400 4520 2270 3330 1670 3200 1620 16 86 3 3 ft 5390 5390 7200 6590 6120 3380 4220 2250 3180 1820 15 49 6 6 ft 6860 6720 4650 3450 2960 2370 12 94 B...

Page 333: ...15 Steel track Counterweight 440 kg 970 Ib Dozer blade Down 16 5 ft 3060 2960 12 05 13 2 ft 2830 2600 2560 2000 15 32 9 9 ft 3000 2560 2900 1760 2400 1640 17 17 6 6 ft 4530 3810 3510 2440 3040 1720 2400 1470 18 11 3 3 ft 5990 3500 4100 2310 3260 1660 2520 1410 18 33 0 ft 3370 3370 6610 3320 4440 2210 3340 1620 2800 1450 17 83 3 3 ft 4560 4560 6410 6360 6320 3270 4330 2170 3000 1610 2970 1600 16 56...

Page 334: ...16 Rubber pad Counterweight 440 kg 970 Ib Dozer blade Down 16 5 ft 3060 2990 12 05 13 2 ft 2830 2630 2560 2030 15 32 9 9 ft 3000 2590 2900 1790 2400 1660 17 17 6 6 ft 4530 3850 3510 2470 3040 1750 2400 1490 18 11 3 3 ft 5990 3540 4100 2340 3260 1690 2520 1430 18 33 0 ft 3370 3370 6610 3370 4440 2240 3340 1640 2800 1470 17 83 3 3 ft 4560 4560 6410 6410 6320 3320 4330 2200 3000 1630 2970 1620 16 56 ...

Page 335: ...ignature and stamp Date Hours Service and maintenance Service 2000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 2500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 3000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 3500 hours Type of service Signature and stamp Date Hours Service an...

Page 336: ...amp Date Hours Service and maintenance Service 6500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 7000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 7500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 8000 hours Type of service Signature and stamp Date Hours Service and maintenance S...

Page 337: ...p Date Hours Service and maintenance Service 10500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 11000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 11500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 12000 hours Type of service Signature and stamp Date Hours Service and maintenance...

Page 338: ...ut system 114 Control types for X1 and X3 operation 85 Controls 100 Coolant 274 301 Coolant level checking 258 Cutting edge replacing 291 D Declaration of Conformity 20 Delivery Inspection 247 Delivery Instructions 247 Demolition work 190 Digging forces 325 Dimensions 320 Disconnecting from an attachment quick coupler hydraulic 213 Disconnecting with pivot pins 210 Display unit 45 Door 120 E Elect...

Page 339: ...l storage 123 P Paint finish maintenance 282 Parking 163 Product plates 25 R Radiator and coolers cleaning 270 286 Recommended bucket sizes 324 Recommended intervals for critical parts 295 Recommended lubricants 298 Refrigerant 245 Regeneration 155 Retrieving and towing 165 Roof 122 Rules for digging 176 Running in instructions 136 S Safety components 24 Safety rules when operating 142 Seat belt 1...

Page 340: ...ter and on boggy ground 186 Working on slopes 185 Working ranges 322 Working where there is risk of landslip 188 Working with buckets 204 Working with hammer 206 Working within dangerous areas 179 X X1 residual pressure release 214 Alphabetical index 339 ...

Page 341: ...340 Alphabetical index ...

Page 342: ...Ref No 20044040 C 2018 05 Volvo Changwon ...

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Summary of Contents for EC60E

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