Volvo ECR50D Operator'S Manual Download Page 175

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Service and maintenance

Lubrication and service chart

Summary of Contents for ECR50D

Page 1: ...ECR50D ECR50D operator s manual Ref no PUB20036502 A 2014 05 Volvo Konz English English ...

Page 2: ...d 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 their des...

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: ... be specified when contacting the manufacturer to order spare parts Positions and explanation of the PIN plates see page 20 Manufacturer Volvo Construction Equipment sas rue Pierre Pingon BP 01303 Belley Cedex France PIN Product Identification Number of machine Engine Foreword Identification numbers 3 ...

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Page 6: ... Instrument panels 26 Instrument panel left 27 Display unit 28 Instrument panel right 43 Other controls 48 Controls 48 ROPS 55 Operator comfort 57 Climate control system 65 Operating instructions 66 Safety rules when operating 68 Measures before operating 73 Starting engine 74 Stopping 76 Parking 77 Retrieving and towing 79 Attachments alternative lowering 81 Transporting machine 83 Table of conte...

Page 7: ... Lifting objects 124 Signalling diagram 128 Safety when servicing 131 Service position 132 Before service read 133 Entering leaving and climbing the machine 136 Fire prevention 137 Handling hazardous materials 140 Handling line tubes and hoses 143 Service and maintenance 144 Service points 149 Engine 151 Fuel system 152 Engine air cleaner 154 Cooling system 156 Electrical system 160 Travel gearbox...

Page 8: ...186 Engine 187 Electrical system 188 Cab 190 Hydraulic system 193 Specifications 194 Machine weights 195 Ground pressure 196 Dimensions 197 Working ranges 199 Recommended bucket sizes 200 Digging forces 201 Lifting capacities 202 Hammer 205 Service history 206 Alphabetical index 211 Table of contents 7 ...

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Page 10: ...r areas with dust containing asbestos special safety regulations are to be followed and the machine to 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 applicable to all handling of the mac...

Page 11: ...Guard Level 1 on top ISO 10262 The OPG level 2 is available as an option These tests are based on the heaviest machine weight configuration unless otherwise stated If any part of the cab s protective structure is affected by plastic deformation or rupture the cab must be replaced immediately The cab is featured with heating and ventilation The side window can be opened and used as exit in case of ...

Page 12: ...y Volvo Construction Equipment Volvo Construction Equipment reserves the right to reject all warranty claims that have arisen due to or can be traced to unauthorized modifications Unauthorised modifications on the upperframe can have an influence on the ROPS protection system which is intended to secure the driver in case of an accident Modifications may be considered to be officially approved if ...

Page 13: ...e The tracks are each driven by a two speed travel motor Slewing system The slewing ring is driven by a hydraulic motor which is protected against excess pressure by high pressure relief valves 12 Presentation ...

Page 14: ...ing on the required information level CareTrack makes it easier to plan for service and reduces costly downtime Productivity is improved by knowing if machines are being operated correctly and how much fuel is being consumed CareTrack also allows the customer to restrict the operating area of the machine by using virtual fences This helps to eliminate unauthorized machine use and theft For further...

Page 15: ...ne in front of the cooling package Open the engine hood to access it The machine comes with a number of tools see below 1 2 3 4 5 V1139940 Tools in the toolbox 1 Wrench with different sizes of nuts 2 Grease gun 3 with cartridge 4 and extension 5 V1139939 1 1 Tool box 14 Presentation ...

Page 16: ...tional 2 Bucket cylinder 11 Undercarriage 3 Dipper arm 12 Travel motor 4 Dipper arm cylinder 13 Tracks 5 Boom 14 Superstructure 6 Boom cylinder 15 Boom offset cylinder 7 Working lights 16 Dozer blade 8 Rear hood 17 Dozer blade cylinder 9 Engine hood 18 Battery disconnect switch Presentation Machine view 15 ...

Page 17: ...t is sold If the machine is used for other applications or with other attachments than described in this manual safety must always be ensured in each individual case A change may in certain cases require a new CE marking and issuing of a new EU Declaration of Conformity The person responsible for this is the same person who makes the change EU EMC Directive The machine s electronic equipment may i...

Page 18: ...If other electronic equipment is fitted to this machine the equipment must be CE marked and tested on the machine with regard to electromagnetic interference Presentation CE marking EMC directive 17 ...

Page 19: ... Directive Machinery 2006 42 EC EC Directive Noise Emission 2000 14 EC EC Directive EMC 2004 108 EC As well as EC Directive Low Voltage 2006 95 EC for electric heating electric generator Applied harmonized standards especially EN 474 1 and EN 474 5 The EN and ISO Standards specified under Chapter 2 of EN 474 1 and EN 474 5 The assessment of conformity method used to determine the guaranteed sound ...

Page 20: ...ptation to the surrounding area The aerial downlead must be of the coaxial cable type Make sure that the cable is undamaged that the screen is not split at the ends and that it thoroughly surrounds the contact sheaths and has good galvanic contact with the same The surface between the mounting bracket for the aerial and the point of attachment must be free from dirt and oxide Apply corrosion prote...

Page 21: ...address of manufacturer model type designation and 17 digit PIN number The supplementary plate contains information about machine mass in kg engine net power in Kw manufacturing year machine serial number and a CE mark Machine mass The machine mass in kg on the supplementary PIN plate is based on the most standard definition of the machine in accordance with ISO 6016 For safety reasons 103 of the ...

Page 22: ...PS ROPS and OPG plate The plate is located inside the cab above the rear windscreen TOPS Tip Over Protection Structure and ROPS Roll Over Protection Structure provide roll over protection in case the machine should turn over OPG Operator Protective Structure provides protection against falling down objects Presentation Product plates 21 ...

Page 23: ...plates must be kept free from dirt so that they can be read and understood If they have been lost or no longer are legible they must be replaced immediately The part number order number is given on the respective plates decals and in the Parts Catalogue NOTE The word WARNING is given on the warning decals for North America 2 1 3 2 4 3 1 10 11 15 14 13 3 2 12 3 9 7 6 5 8 2 16 17 18 19 20 V1139399 D...

Page 24: ...e 2 tie down points on undercarriage 4 WARNING Track tension check the tension every day Read the Operator s Manual V1129955 5 WARNING Fasten seat belt when operating the machine V1129954 6 WARNING Move the control lockout lever up to lock the system securely when leaving the machine V1142086 7 Battery disconnect switch 11802898 V1089393 8 Slewing ring lubrication Presentation Information and warn...

Page 25: ...not enter the machine s working area Risk for crushing 14 Fuel filler point V1142089 15684289 P01 N N X3 A B 3s X1 A B ISO RH STD RH STD LH ISO LH 15 Operator s stand control elements 70 C 158F 20 C 68F Max Min V1128010 16 Read and understand the hydraulic oil filling instruction before filling 24 Presentation Information and warning decals ...

Page 26: ...il filler point 18 Lubrication and maintenance chart V1065366 19 Volvo Coolant VCS For coolant specifications see page 156 V1065344 20 WARNING Hot coolant under pressure Presentation Information and warning decals 25 ...

Page 27: ...n and position of the instruments and operating controls Carefully read through this Operator s Manual your safety is involved Keep the manual in the cab so that it is always at hand when needed V1140444 1 2 1 Instrument panel left 2 Instrument panel right 26 Instrument panels ...

Page 28: ...ngle acting system The attachment bracket is opened by pushing the red button up and pressing down the lower end of switch 1 As soon as you release the switch the attachment bracket is locked Double acting system The attachment bracket is opened by pushing the red button up and pressing down the lower end of switch 1 When you release the button the attachment bracket will remain unlocked To lock t...

Page 29: ...lay panel 3 Fuel level gauge 4 Engine coolant temperature gauge 5 Seat belt not fastened 6 Offset boom activated 7 Dozer blade floating not applicable for ECR50D 8 Overload warning function activated 9 Engine oil pressure low 10 Attachment bracket open 11 12 Regeneration symbols not applicable for ECR50D 13 Power socket 1 Central warning lamp red The central warning lamp in the display unit lights...

Page 30: ...he right end to indicate engine overheated NOTE Shut down the engine immediately if the gauge shows an overheating of the engine and the central warning lamp 1 lights up 5 Seat belt not fastened red This lamp lights up if the seat belt is not fastened when the engine is running NOTE Never operate the machine without having the seat belt fastened your safety in involved 6 Offset boom activated gree...

Page 31: ...tachment bracket open red This lamp lights up if the attachment bracket is open 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 the attachment bracket is properly locked before starting to work again 11 12 Regeneration...

Page 32: ...how up on the display The main screen is divided in three parts The top part shows the engine speed in rpm The lower parts shows the actual time and information icons like service anti theft machine message or preheating Setting date and time The setting mode screen for the current date and time appears when pressing the SELECT button from the main screen Use the arrow buttons to adjust and then p...

Page 33: ...for the boom offset swing speed appears when pressing the SELECT button from the boom offset screen Select the boom speed setting for both directions symmetrical or independently left side or right side non symmetrical and press SELECT to adjust the speed with the arrow buttons Use arrow up for increasing and arrow down for decreasing the speed Each bar on the graph corresponds approximately 12 5 ...

Page 34: ...ht side non symmetrical and press SELECT to adjust the flow with the arrow buttons Use arrow up for increasing and arrow down for decreasing the maximum flow Each bar on the graph corresponds approximately 12 5 of maximum flow Select the characteristics of the X1 mode in the mode menu by choosing between active normal and soft mode Active mode Max flow is activated without ramp up Normal mode Max ...

Page 35: ...ar on the graph corresponds approximately 12 5 of maximum flow Select the characteristics of the X3 mode in the mode menu by choosing between active normal and soft mode Active mode Max flow is activated without ramp up Normal mode Max flow is activated with small ramp up Soft mode Max flow is activated with slow ramp up Press the SELECT button to save the setting or press ESC to escape without sa...

Page 36: ...imes from the main screen The basic concept of the automatic engine shut down is to reduce the fuel consumption and reduce maintenance cost by avoiding additional operating hours The engine will be shut down automatically after a preselected amount of idling time if the function is activated and no control levers or pedals nor the control lockout lever or the engine speed control are operated This...

Page 37: ...ELECT from the keypad backlight screen to enter the brightness setting screen Use the arrow up and arrow down buttons to adjust the brightness of the keypad backlight Each bar on the graph corresponds approximately 12 5 Press the SELECT button to save the setting or press ESC to escape without saving Anti theft screen The anti theft screen appears when pressing arrow down nine times from the main ...

Page 38: ...ue This symbol is shown if an error occurs in the engine controller The engine rpm can not be changed anymore Put the machine in a safe place turn it off and contact your authorized Volvo Construction Equipment workshop Boom swing max flow setting This symbol is shown when the boom swing maximum flow is adjusted with the joystick see page 48 for further information The symbol is shown also during ...

Page 39: ...ssure is too low Additionally the buzzer sounds during the countdown for the engine shut down The shut down can be postponed for 1 minute during the countdown by pressing the ESC button on the keypad During this additional 1 minute the machine can be moved out of a possible dangerous area Investigate the cause and contact your authorized Volvo Construction Equipment workshop if necessary Engine hi...

Page 40: ...ow This symbol is shown if the engine oil pressure is too low Turn off the engine investigate the cause and contact your authorized Volvo Construction Equipment workshop if necessary Battery charge error This symbol is shown if the battery is not being charged or the system voltage is too low Investigate the cause and contact your authorized Volvo Construction Equipment workshop Overload warning o...

Page 41: ...Engine high coolant temperature countdown finished This symbol is shown when the engine was shut down automatically due to high engine coolant temperature Investigate the cause and contact your authorized Volvo Construction Equipment workshop if necessary Theft protection Anti theft system The anti theft system prevents theft of the machine since the machine can only be started with the correct 4 ...

Page 42: ... the first code and press SELECT to change this code Enter the old primary code and press SELECT Enter the new code and press SELECT Repeat the new code and confirm with SELECT A confirmation screen appears for 2 seconds if the old code is correct and the new code is correctly repeated If the old code or the new code are incorrect the change screen is shown again Change secondary code Press SELECT...

Page 43: ... is correctly repeated If the old code or the new code are incorrect the change screen is shown again Enable or disable the anti theft system Press SELECT when the main screen is shown Select the fourth item press SELECT to enable or disable the anti theft system Select the first item with the locked symbol to enable the anti theft and confirm with SELECT Select the second item with the unlocked s...

Page 44: ...ad The keypad is used for the display unit and also to directly control several functions For information about the display unit see page 28 NOTE The buttons with numbers 0 9 are also used to enter the code for the anti theft system 1 Fast travel speed 2 Air conditioning 3 Auto idle 4 Working lamps front and boom rear 5 Overload warning 6 X3 setup if option is installed or X1 setup 4 if no X3 is i...

Page 45: ...ver see page 48 2 Air conditioning optional equipment Press this button to switch the air conditioning on and off The button is alight if the air conditioning is activated Use the regulator 6 temperature control to set up the desired temperature of the air conditioning 3 Auto idle Automatic engine speed control With this button the auto idle system can be activated or deactivated The button is ali...

Page 46: ...d or X1 max flow setting 4 if no X3 is installed on machine The button will be alight if X3 max flow or X1 max flow setting 4 is under use Press the button for 2 seconds to store new setting under this button Factory settings 100 X1 X3 7 X1 setup 1 Press this button to activate X1 max flow setting 1 The button will be alight if X1 max flow setting 1 is under use Press the button for 2 seconds to s...

Page 47: ...o increase the engine RPM 16 not assigned This key is not assigned on the ECR50D 17 RPM user setup 1 Press the RPM user setup 1 button to set the engine RPM to the value stored under this button The button is alight if the RPM user setup 1 is activated Press this button during 2s to store a new engine RPM value under this button 18 RPM down Press this button to reduce the engine RPM 19 RPM user se...

Page 48: ...Press upper end of switch The fan is in high position Switch in middle position The fan is in low position Press lower end of switch The fan is off 5 Switch for windscreen wiper and washer Three position switch Press upper end of switch The windscreen wiper and windscreen washer is on press and hold to activate and release to stop Switch in middle position The windscreen wiper is on Press lower en...

Page 49: ...achments 4 Control lockout lever for hydraulics 5 Control levers for travel motion 6 Right hand control lever for working equipment 7 Selector switch offset boom or attachment movement 8 Switch for optional equipment such as hammer 9 Proportional roller for optional equipment 10 Dozer blade control lever with switch for fast travel speed 48 Other controls Controls ...

Page 50: ...rward Extending the dipper arm Lever backward Retracting the dipper arm Lever to the right Slewing movement to the right Lever to the left Slewing movement to the left Left control lever for working equipment SAE control pattern optional equipment Lever forward Boom down Lever backward Boom up Lever to the right Slewing movement to the right Lever to the left Slewing movement to the left 2 Horn Bu...

Page 51: ...for working and travel hydraulics are unlocked working position 5 Control levers for travel motion WARNING Risk of fatal accidents Unexpected driving direction could lead to accidents resulting in serious injury or death Always check the driving direction before moving the machine When the dozer plate is in rear position 180 rotation the travel system operation is reversed Push both levers forward...

Page 52: ...to the right Empty the bucket opening Lever to the left Fill the bucket closing Right control lever for working equipment SAE control pattern optional equipment Lever forward Extending the dipper arm Lever backward Retracting the dipper arm Lever to the right Empty the bucket opening Lever to the left Fill the bucket closing 7 Selector switch offset boom or attachment movement When actuating this ...

Page 53: ...al equipment or boom offset to the desired direction For example thumb closes or offset boom to the right Hydraulic oil flow changing maximum setting for X1 and X3 There is a possibility to set the maximum hydraulic oil flow used for the first auxiliary X1 and for X3 1 Select the boom offset mode NOTICE Boom offset must be selected before changing the maximum hydraulic oil flow setting If attachme...

Page 54: ...ller in this position and press the selector switch for offset boom or optional equipment 8 on the right control lever to confirm 5 The setting menu will turn off automatically after 5 seconds if no roller or switch is activated To validate and exit menu Press the selector switch for offset boom or optional equipment 7 and then at the same time press switch for optional equipment 8 on the right co...

Page 55: ... the keypad does not have to be activated ISO SAE selector optional equipment WARNING Risk of serious accidents 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 The ISO SAE selector valve optional equipment is located ins...

Page 56: ...rotective Guards level 1 OPG1 when the front windscreens are in place and locked down Toughened glass will protect the operator from debris projection for example during breaker operations To comply with Operator Protective Guards level 2 OPG2 machines must be equipped with An additional top protective structure made of solid steel plates This guard will protect the operator from an object of 227K...

Page 57: ...n operating with a hammer hydraulic breaker protective roof and window guards should be installed If you have a canopy version of the machine a hammer hydraulic breaker protection kit is also available Consult your local Volvo Construction Equipment dealer for information about when the different options can be used NOTICE Always check clearance between bucket and Cab OPG guard Slowly cycle bucket...

Page 58: ...jury Always lock the control lock out lever before adjusting the seat Horizontal adjustment Pull lever 1 slightly up Adjust the seat to the desired position Check that the seat has properly engaged Backrest adjustment Pull lever 2 slightly up Adjust the inclination of the backrest Once the backrest is locked in position the inclination can no longer be changed Pull the lever up again to unlock and...

Page 59: ...ged or has been stretched in an accident must be replaced immediately Every 3 years the seat belt must be changed regardless of its condition The seat belt must be replaced by your Volvo dealer Modifications to the belt or its mountings are not permitted The belt is intended for one adult person only Change the belt every three year regardless of its condition When the seat belt needs to be washed...

Page 60: ...cab roof 1 Place the upper windscreen under the cab roof 2 Push buttons 11 on both sides of the lower windscreen to remove it 3 Loosen the upper windscreen from the roof and push it down 4 Place the lower windscreen in front of the upper 5 Push both of the windscreens up under the cab roof Make sure you hear a click then the windscreens are fastened Working lights Working lights 8 are used to illu...

Page 61: ...e cabin door Make sure that the cab is parallel to tracks when entering the machine That allows best possible access situation Roof If any part of the cab s protective structure is affected by plastic deformation or rupture the cab shall be immediately replaced Do not jump out of cab if the machine should roll over Keep stay in seat wearing seat belt Protection from falling or scattering materials...

Page 62: ... Operator s manual storage The Operator s Manual must be stored in the storage box 1 on the backside of the operator seat Fire extinguisher location Possible location for a fire extinguisher is behind the seat with a special fixation bracket offered by Volvo Construction Equipment Contact your dealer for further information about this fire extinguisher fixation bracket Emergency exit The alternati...

Page 63: ... side of the machine Check which of the two radio versions is built in your machine Radio with CD 1 Mute Power 10 Preset 5 2 Sound styles 11 Preset 4 3 Eject 12 LCD 4 CD door 13 Preset 1 5 Band 14 Preset 2 6 Search up 15 Preset 3 7 AST RDS 16 Volume 8 Search down 17 Volume 9 TA AF 62 Other controls Operator comfort ...

Page 64: ...USB REAR SD AUX FRONT or AUX REAR source Long press Activate Travel Store function in radio mode 2 ON OFF button Short press Switch on sound system In operation Mute sound system Long press Switch off sound system 3 Volume control Adjust the volume In the menu Change the settings Fast Browse mode Select folder and track 4 Display 5 SEARCH CHANGE SELECT button UP DOWN In the menu Select menu item R...

Page 65: ...tion in the current memory bank in radio mode 9 MENU button Short press Open and close the menu Long press Start the scan function 10 Green phone button Short press Answering a call special dial Long press Activate voice dialing 11 Red phone button Ending rejecting a phone call 12 SD card slot 13 DISP button Switch display 64 Other controls Operator comfort ...

Page 66: ...the fan are only operable when the engine is running The air condition is switched on and off with a button on the keypad and the temperature is adjusted by a regulator on the right instrument panel For further information see page 43 Other controls Climate control system 65 ...

Page 67: ...between bucket and ground A should be 400 mm 15 7 in It may not be possible to provide direct visibility to all areas around the machine To achieve acceptable visibility additional devices such as warning systems and mirrors can be used In order to minimize hazards that may be caused by restricted visibility rules or procedures should be established by the work site management For example Make sur...

Page 68: ...in according to ISO 5006 and ISO 14401 And it shall be equipped with optional visibility enhancing devices as needed Measures before and during operation Walk around the machine and check that there are no obstacles next to the machine Check that mirrors and other visibility enhancing devices are in good condition clean and correctly adjusted Check that the horn back up travel alarm and rotating w...

Page 69: ...th how to operate and maintain the machine and should undergo adequate training on the machine The operator must follow the Operator s Manual rules and recommendations but also pay attention to any statutory and national regulations or specific requirements or risks which apply at the work site The operator must be thoroughly rested and must never operate the machine when under the influence of al...

Page 70: ...s not apply if the cab is sufficiently strong or protected to withstand the impact of such external forces Make sure you know the weight limitation of working ground Only the operator seated in the operator s seat may be in the cab when operating All other personnel must keep at a safe distance from the machine WARNING Risk of fatal accidents Using attachments for lifting or transporting persons m...

Page 71: ...and a hard hat should be worn Keep your hands away from areas where there is a risk of crushing e g covers door and window Use steps and handholds when entering or leaving the machine Use the three point grip i e two hands and one foot or two feet and one hand Always face the machine do not jump Check that the attachment is properly attached and locked The vibration shaking which arises when opera...

Page 72: ...stability of the machine is subjected to considerable changes The operator himself must observe all special regulations applicable to every operation in order to obtain full working safety NOTE A pre requisite for good stability is that the machine is parked on level ground of sufficient load bearing capacity Care should be taken if the ground is soft and uneven sloped in danger of collapsing side...

Page 73: ...se parts show any abnormality before the replacement interval has passed they should be repaired or replaced immediately If the hose clamps show any 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 trained personnel ...

Page 74: ...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 operator seat and fasten the seat b...

Page 75: ...s out after preheating However if the ignition key remains in preheating position 2 the preheating function remains active even though the control lamp is off 7 Once the preheating control lamp has gone out turn the ignition key to start position 3 and start the engine As soon as the engine starts release the ignition key Do not continue to start for longer than 25 seconds without interruption 8 I...

Page 76: ...tion key while the engine is running as this will generate a surge voltage that may damage the electrical system 1 Start the engine 2 After a longer period of standstill and particularly at temperatures around or below the freezing point the excavator must be warmed up by running the engine at medium speed 3 Run the excavator warm for about 5 to 10 minutes at approx 50 engine speed During this per...

Page 77: ...ngine off position 0 to shut down the engine 5 All control lamps go out 6 Check whether all switches and controls are switched off or deactivated 7 Remove the ignition key to prevent unauthorised use of machine 8 Interrupt the electric supply with the battery disconnect switch NOTE If you want to stop all movements of the machine quickly without turning the ignition key shift the control lockout l...

Page 78: ...ti freeze in the cooling system see page 156 and in the windscreen washer reservoir if the temperature can fall below 0 C 32 F during parking 6 Close and lock windows door and covers 7 Disconnect the battery by turning the battery disconnect switch to off position and remove the key Keep in mind that the theft and burglary risk can be minimised by removing the starter key when the machine is left ...

Page 79: ... the machine thoroughly and grease all unpainted surfaces like cylinder rods etc 6 Fill the fuel tank and the hydraulic oil tank to the max marks 7 Cover the exhaust pipe for outdoors parking 8 Drain water from any compressed air reservoirs if installed 9 Make sure the freezing point of the coolant is sufficiently low in cold weather 10 When storing machines in extreme cold temperatures remove bat...

Page 80: ...nnel to stay clear of the tow vehicle and the disabled machine during the towing process In the event of slipping into swampy ground or towing heavy objects proceed as follows 1 Attach a wire rope to the machine to be retrieved or towed as shown in the illustration Ensure that the towing linkage is properly connected adequate for the purposes NOTE Put wood blocks between the wire rope and the mach...

Page 81: ...f 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 80 Operating instructions Retrieving and towing ...

Page 82: ...attachment with the control levers 1 Insert the ignition key into the ignition switch and turn it to running position ignition 2 Shift control lockout lever 4 to position B The control levers for working and travel hydraulics are unlocked movement possible 3 The control levers see page 48 can be used to lower the attachment NOTE If lowering of the attachment is not possible because the accumulator...

Page 83: ...e boom without any additional action This means that pushing forward any control lever can move the equipment down even if the control lockout lever is in locked position A 3 Use the control levers to lower the attachment 4 Retighten the screw C NOTE If you do not retighten the screw the function of the control lockout lever will not work NOTE Before lifting the control lockout lever to position A...

Page 84: ...is 90 km h 55 mph according to European legislation If the speed is higher than 90 km h 55 mph there is a risk of the roof coming apart during transport In some countries e g USA the speed limit can be 130 km h 80 mph In this case add an additional belt to secure the roof Lifting machine WARNING Risk of personal injury Faulty or improper lifting equipment could cause the machine to break away from...

Page 85: ... in the upper end position 6 Make sure that nobody is in the machine while lifting 7 Use suitable lifting equipment to lift the machine Make sure that the lifting chains are strong enough for the weight of the machine For machine weight see page 195 NOTE Volvo is not responsible neither for lifting equipment nor for lifting techniques 8 The distance C between axis A and B at the lifting point on t...

Page 86: ...his will reduce the total height of the machine Tying down machine 3 3 1 2 2 1 3 V1142524 1 Align the machine s tracks to the ramp the dozer blade to the front facing the cabin of the truck and the attachments to the front position 2 Never operate any lever other than the travel levers pedals while the machine is on the loading ramp 3 Park the machine on the trailer 4 Rotate the slewing superstruc...

Page 87: ...rm of the trailer Unloading 1 Remove the chains belts and wheel chocks 2 Raise excavating equipment and dozer blade 3 Remove the wooden blocks below the attachment and the dozer blade 4 Slowly drive to the beginning of the ramp lift the excavating equipment position and drive forwards until the machine tips on to the ramp 5 Drive down slowly until the machine reaches level ground 86 Operating inst...

Page 88: ...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 87 ...

Page 89: ...es not consume any fuel Plan your work site Take stock of your work area and plan its layout with regard to the machines that will work there Your work will be much more productive and organized Keep the ground even and free from larger stones or other objects that form obstacles Cooperate Consult with other operators so that machines and trucks work together in the most effective way Use the righ...

Page 90: ... 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 recommendations Track tension Brake and steering systems Controls hydraulic system a...

Page 91: ... 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 lifting of loads Maintain reasonable weight and physical condition 90 Operating techniques Whole body vibrations ...

Page 92: ...es Make sure that they take care No persons apart from the operator may unnecessarily 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 forming If the ...

Page 93: ... 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 High voltage is lethal and the current sufficiently strong to destroy both machine and attachments Your life is in danger if you come into contact with or close to high voltage power lines Always contact the power ...

Page 94: ...erceived 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 machine whenever it is close to power lines Prohibit ...

Page 95: ...After any breaks in the work always contact the railway personnel again Underground cables and pipes Make sure that authorities or companies responsible for cables and pipes have been contacted and that their instructions are followed Also check which rules apply to ground personnel regarding exposing cables and pipes Normally only the service companies own personnel may expose and arrange provisi...

Page 96: ...ble gradients b engine lubrication Manageable gradients c engine lubrication α 17 5 31 5 α 35 70 α 30 57 a α 50 of tipping limit b manageable gradient for maximum 3 minutes c manageable gradient continuous Be careful when opening or closing the doors on a slope operational force may be changed rapidly Make sure to keep the doors closed Do not descend backward on a slope Operate the travel function...

Page 97: ...angering the operator and the machine While wading stop the machine now and then and swing the bucket sideways just 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 After working in water the lubrication points on the undercarriage which have been under water must be lubricated so that ...

Page 98: ...d at least 5 m 16 ft away from the edge Do not dig under the machine Do not operate too close to the edge of a steep slope or road bank Take care when working in a place where the machine may tip Take care when working on river banks or in other similar places where the ground is soft There is a risk that the machine because of its own weight and own vibrations may sink and this could lead to acci...

Page 99: ...bjects 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 Read the advice for starting see page 74 The windows must be free from ice and snow before putting the machine to work Watch out for ice on the machine causing slippery condit...

Page 100: ... 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 101: ... any kind of service of the hydraulic system is carried out NOTE Any persons involved in the process of changing attachments must be familiar with the operation of the machine and should know the signalling pattern Using the correct attachment for a particular job is a deciding factor when it comes to the capacity of the machine The machine has either direct mounted attachments or attachments moun...

Page 102: ...bination machine attachment For more detailed information regarding the choice of attachments contact a Volvo Construction Equipment dealer The machine is prepared for various different attachments e g hammer hydraulic breaker In order to be able to connect these hydraulically to the machine the pressure in the hydraulics must be released by moving the control levers in all directions NOTE Dependi...

Page 103: ...injury or death Check relevant machine parts regularly If wear or damage occurs stop operating immediately and call for immediate corrective maintenance Installing a bucket with manual fastening 1 Position the excavating equipment to the bucket to be installed 2 Align bores in dipper arm and bucket 3 Insert a Ø 20 mm 0 787 in assembly rod into the bore 4 Raise the excavating equipment and operate ...

Page 104: ...gth of the dipper arm Be careful when moving the bucket and dipper arm towards the machine there is a risk of damaging the machine 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 Mechanical attachment bracket bucket installation WARNING Risk of cr...

Page 105: ...back 90 9 Insert the locking pin 10 Insert the linch pin through the end of the locking pin 11 Check that the bucket is securely fastened by simultaneously pressing the bucket to the ground and forward Disconnecting bucket 1 Lower the bucket to the ground 2 Extract the linch pin and the locking pin 3 Rotate the locking pin 90 to lock it in extracted position 4 Position the bucket 10 cm 4 in above ...

Page 106: ...et 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 to release the front bucket pin To release the attachment bracket insert the release bar and pull Release the attachment bracket from the bucket Operating techniques Attachment brackets 105 ...

Page 107: ... Shut down the engine and turn the ignition key to running position ignition 4 Move the control lockout lever 4 down to unlock the system 5 Shift the rollers on the joysticks a couple of times to the right and to the left 6 Then move the joysticks and the driving levers in all directions a couple of times to release all residual pressure 7 To release the pressure in the accessory line X1 and boom ...

Page 108: ...NOTE Do not dig the bucket too deep into the ground since this would block the digging action However should this occur slightly raise the boom Work in a smooth way and avoid quick movements Completely close the bucket when filled Raise the boom and simultaneously start the swing motion until the unloading position is reached Backfilling or grading 1 In order to backfill a trench position the mach...

Page 109: ...o the left Roller to the right Offset boom to the right This work can be accomplished under confined spatial conditions The minimum radius R1 of the equipment is as follows Offset in degree ECR50D to left 76 to right 56 ECR50D minimum radius mm in Type Short dipper arm 1400 mm 55 12 in Long dipper arm 1800 mm 70 87 in R1 to left 1948 mm 76 69 in 1984 mm 78 11 in to right 2258 mm 88 90 in 2299 mm 9...

Page 110: ...ressure jetting out and cause serious injury even if the engine has not been running for some time Always release the pressure before any kind of service of the hydraulic system is carried out NOTE Any persons involved in the process of changing attachments must be familiar with the operation of the machine and should know the signalling pattern Volvo supplies a wide range of hydraulic tools All t...

Page 111: ...hammer may be damaged NOTICE If the hammer is connected to an attachment bracket the attachment bracket should be checked regularly for damage 1 Turn the hammer shear valve counterclockwise to horizontal position B to set the hammer position oil direct to tank 2 Prepare the machine for normal excavation work Move the machine to the required position Lower the dozer blade to the ground 3 Set the en...

Page 112: ...gently with the boom 7 Start the hammer Depress button 8 to activate the hammer function Release the button to deactivate the hammer function NOTE Listen to the sound of the hammer when you are using it If the sound becomes weaker and the impact less efficient the tool is misaligned with the material and or there is not enough feed force on the tool Realign the tool and press the tool firmly again...

Page 113: ...irm and level ground 2 Slowly lower and align the boom until fastening bores 2 of the hammer are flush with the holes in the boom 3 Insert pivot pins 1 into fastening bores 2 4 Clean the hydraulic connections on hammer and dipper arm NOTICE Protect the hydraulic connections against dirt because only this will ensure the correct function of hydraulic connections and hydraulic system 5 Release the p...

Page 114: ... on the boom to loosen the hammer Connecting to an attachment bracket For connecting and disconnecting a hydraulic breaker from an attachment bracket refer to the attachment bracket Operator s Manual NOTE Take care during disconnection hydraulic breakers have a high inertia due to the weight and could fall out of the attachment bracket coupler during disconnection Always connect and disconnect as ...

Page 115: ...otective equipment If the machine has a canopy a front protective guard must be used and operator must use safety glasses and a helmet Never start the engine when the hydraulic couplings are disconnected Never leave the machine with engine running and key inserted Before shutting down the engine or leaving the machine lower the bucket to the ground and open the thumb It is dangerous to leave the t...

Page 116: ...pproved for use with Volvo designed or approved buckets and attachments If the thumb is used with other buckets or attachments it may not work properly If the thumb is not used for some time disconnect the hydraulic lines to prevent thumb cylinder drift Connecting and disconnecting thumb 1 If the hammer shear valve in the front of the cooling package is not in the correct position turn it 90 clock...

Page 117: ...ach 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 NOTE Depending on the equipment the hydraulic connections on the boom can vary from the illustration and the description E D V1142526 Right side of the dipper arm 116 Operating techniques Thumb ...

Page 118: ...portional roller on the right lever is now activated for thumb operation 2 Operate the thumb with the proportional roller 9 on the right lever Roller to the right Open the thumb Roller to the left Close the thumb 3 To return to boom offset mode push the button on the right lever again The proportional roller is now activated for boom offset WARNING Risk of crushing Pressure interruption by mode sh...

Page 119: ...or the clamshell laying flat on the ground 2 Slowly lower and align the boom until the fastening bores of the clamshell are flush with the holes in the boom 3 Release the pressure from the hydraulic system 4 If the hammer shear valve in front of the cooling package engine compartment not is in the correct position turn it 90 clockwise to the vertical position A to have the auxiliary line in the do...

Page 120: ...e boom and lay the clamshell flat on the ground 3 Release the pressure from the hydraulic system 4 Disconnect the hydraulic hoses of the clamshell from the hydraulic connections on the boom and close the hydraulic couplings with protective caps 5 Turn the valve on the cylinder to unlock the bucket movement NOTE Lay the clamshell on a pallet This enables easier transport of the clamshell after disa...

Page 121: ...the right multi function lever With the proportional roller 9 the clamshell can be rotated in two directions Control lever to the right Empty the clamshell opening Control lever to the left Fill the clamshell closing 9 10 V1138044 7 8 6 120 Operating techniques Clamshell bucket ...

Page 122: ...ll reduce the falling speed of the boom if a hose bursts Lowering the boom with hose rupture protection In case of standstill or engine defect and power failure during loading operation the accumulator pressure is sufficient to lower the attachment to the ground with the control levers NOTE Too low pressure in the accumulator may make it impossible to lower the attachment Blade float position NOTE...

Page 123: ...over an obstacle a gap is formed between the rollers 1 and track 2 There is a risk of the rubber tracks coming off If the machine continues to reverse a gap is formed between the rollers idler 3 and the track The track may then come off when turning in a condition where the track can not move to the side because of the obstacle it is passing over or because of some other object V1087141 1 2 3 122 ...

Page 124: ...idler or track rollers are no longer aligned with the core because the track has moved out of alignment If the machine is reversed in this condition the track will come off If the machine is turned in this condition the track will come off V1087142 Operating techniques Tracks 123 ...

Page 125: ...ent NOTICE Do not use damaged broken or uncertified lifting devices WARNING Risk of crushing Swinging objects could cause serious injury Always ensure no persons are in the danger zone before lifting or moving objects Various countries have their own regulations concerning the use of the machine for lifting work e g lifting freely suspended loads For more detailed information you should contact yo...

Page 126: ...ngths and track size Choose the correct lifting chart taking into account all attachments and rigging materials that will be used during the lift The weight of the rigging materials and attachments should be deducted from the load capacity Warm up the machine to normal working temperatures Position the machine on firm level ground Properly set outriggers and blade when applicable Once the load is ...

Page 127: ...the values specified in these operating instructions In addition it may be unsuitable to operate at this inclination as the machine may become unstable and unbalanced depending on the load Make sure that the ground is firm and safe Unstable ground for example loose sand or soft earth may make the work unsafe if loads close to the maximum values in the loading table are taken Do not make fast slewi...

Page 128: ...f the overload warning lamp lights up you have reached the maximum lifting limit Immediately lower the equipment and unload some of the weight or move to a more safe position where the light does not illuminate For lifting capacities specifications see page 202 Operating techniques Lifting objects 127 ...

Page 129: ...ven 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...

Page 130: ...g horizontally at closed hand OPEN BUCKET Hold one hand open and stationary Rotate other hand in small vertical circle with forefinger pointing horizontally at open hand TURN Raise forearm with closed fist indicating inside of turn Move other fist in vertical circle indicating direction of track or wheel rotation V1104052 V V1065936 V1065937 TURN Raise forearm with closed fist indicating inside of...

Page 131: ...er arm extended laterally hand open downward move arm back and forth EMERGENCY STOP With both arms extended laterally hands open downward wave arms back and forth V1065922 V1104053 V1104054 STOP ENGINE Draw thumb or forefinger across throat RETRACT TELESCOPIC DIPPER ARM With either arm outstretched horizontally in front of body close fingers and point thumb in direction of required movement EXTEND...

Page 132: ...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 131 ...

Page 133: ...ot machine parts to cool before performing adjustments or service Wear personal protective equipment Pull the ignition key off and pull down the control lockout lever in order to eliminate the risk of unintended starting of the engine Turn the battery disconnect switch off when servicing the machine The stability of the machine is a prerequisite for safe assembly maintenance and repair work When r...

Page 134: ...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 will jet out When checking for leaks use paper or hardboard not your hand Make sure that stepping surfaces handholds and anti slip surfaces are free from oil diesel fuel dirt and ice Never step on parts of the machine...

Page 135: ...Release the pressure in the hydraulic system before starting the service work 134 Safety when servicing Before service read ...

Page 136: ...her liquids dangerous to the environment and released into the environment will cause damage Oil degrades very slowly in water and sediment One litre of oil can destroy millions of litres of drinking water NOTE In common for all points below is that all waste is to be handed over to a treatment and disposal firm approved by the authorities When draining oils and liquids must be collected in suitab...

Page 137: ...dholds Always face the machine when entering the cab Leaving cab Stop engine and remove key before leaving the cab to prevent unauthorised use of machine Make sure that the cab is parallel to tracks that allows best possible leaving situation Use the three point approach to leave the cab by using two hands and one foot or one hand and both feet Use stepping surfaces and handholds Always face the m...

Page 138: ...de 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 or have an open flame near a machine when filling with fuel or when the fuel system is opened and in contact with the surrounding air Diesel fuel is flammable and must not be used for clean...

Page 139: ...tely high pressure and temperature Protect electrical leads in an appropriate way Take extra care when cleaning a machine working in a fire sensitive environment for 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 138...

Page 140: ...ng steps at the slightest sign of fire 1 Stop the machine if the machine is in motion 2 Lower attachments to the ground 3 Move the control lockout lever to locked position if so equipped 4 Turn the ignition key to stop position 5 Exit the cab 6 Call the fire brigade 7 If possible to access safely turn off the battery disconnect switch 8 Attempt to put out the fire if possible Otherwise move away f...

Page 141: ...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 142: ...a part which has been very hot and which may be made of fluoro carbon rubber should be decontaminated by thorough and ample washing with lime water As a precaution all seals O rings and other oil seals should be handled as if they were made of fluoro carbon rubber The hydrofluoric acid may remain on the machine parts for several years after a fire If swelling redness or a stinging feeling appears ...

Page 143: ...Do not connect a discharged battery in series with a fully charged battery Risk for explosion Discarded batteries must be taken care of according to national environmental requirements Starting with booster batteries see page Starting with booster batteries Charging batteries see page 162 Crystalline silica quartz dust Crystalline silica is a basis component of sand and granite Therefore many acti...

Page 144: ...o not use your bare hand to check for leaks Tighten all connections Consult your Volvo dealer for the recommended tightening torque If any of the following conditions are found replace the parts Consult your Volvo dealer End fittings are damaged or leaking Outer coverings are chafed or cut Strengthening wires are exposed Outer coverings are ballooning Flexible part of the hoses are kinked End fitt...

Page 145: ...ch the operator can carry out If certain operations require trained workshop personnel and special equipment this will be indicated See page 174 Service history After each completed service at a workshop authorised by Volvo Construction Equipment the service history should be filled in see page 206 Service history is a valuable document which can be referred to when for example selling the machine...

Page 146: ...o n OnMotorGrad ers lean the front whee ls left an d right Hydraulicsystem Run allhydrau lic cylinderstotheir r espe ctiveend p osition Checkallequip ment an d functions 10 Check tha t the re a re nofuel wa ter oroil leaks If n ecessa ry check tigh ten conn ectio ns clam ps and fittings 11 Anymalfunctions or defect s mustbe corrected no ted and rep ortedto the su pervisor See p age 2 12 Turn of f ...

Page 147: ... wastes daily Daily clean the areas on the machine where dust chips and similar may collect in order to minimise the risk of fire see page 137 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 in between nozzle and machine s...

Page 148: ...aint finish At first clean the machine Rectify any damage to paint finish in a professional way Cleaning engine compartment WARNING Risk of serious injury Moving parts could cause serious cutting or crushing injury Stop the engine before opening the engine hood and performing any work WARNING Risk of burns Engine and exhaust system components get very hot and can cause severe burns Avoid contact w...

Page 149: ...ed with for example compressed air Cleaning should preferably be carried out at the end of the working shift before the machine is parked Use personal protective equipment such as protective goggles gloves and respirator After cleaning check and rectify any leaks Close all covers and hoods 148 Service and maintenance ...

Page 150: ...ry 3 Hydraulic tank breather 4 Hydraulic oil tank 5 Hydraulic oil filter 6 Hydraulic oil level sight glass filling and drain filter 7 Fuel filler neck 8 Fuel filter 9 Air filter 10 Water separator 11 Expansion tank 12 Radiator Hydraulic oil cooler 13 Engine oil filter Service and maintenance Service points 149 ...

Page 151: ...14 Engine oil dipstick 15 Engine oil filler neck 150 Service and maintenance Service points ...

Page 152: ... Open the engine hood 4 Pull out the dipstick 1 and wipe it clean with a lint free cloth reinsert it until it bottoms and pull it back out 5 The oil level should reach the upper mark MAX 6 If the oil level is near or even below the bottom mark MIN top up oil immediately through the engine oil filler neck 2 to avoid severe engine damage for quality of oil refer to the table of fuels and lubricants ...

Page 153: ...ach working day This prevents the formation of condensation water as far as possible In case of excessive contamination of the fuel the fuel tank can be drained via the drain plug under the tank on the left hand side of the frame by a service technician Check the fuel tank capacity on page 186 Fuel filling 1 Park the machine on level ground and place it in service position see page 132 2 Turn the ...

Page 154: ...mum condensation water level in the water separator 5 Place a suitable container underneath the drain hose 4 of the water separator 6 Close the fuel valve 1 by turning it clockwise to position B 7 Turn and loosen the drain cock 3 on the underside of the water separator with your hand 8 Drain the accumulated water through the drain hose 4 into the container NOTE Carry out the work in an environment...

Page 155: ...placing Primary air filter cleaning NOTE Avoid damaging or denting of the front face of the filter Do not try to clean the filter cartridge by banging it against a hard object Clean the primary filter as needed 1 Park the machine on level ground and place it in service position see page 132 2 Turn the battery disconnect switch off 3 Open the engine hood 4 Open the locking hooks for the housing lid...

Page 156: ...lier if clogging signal goes on Contact your Volvo Construction Equipment dealer Secondary air filter replacing optional equipment The secondary filter must be replaced when the primary air filter was replaced three times or every second year Contact your Volvo Construction Equipment dealer NOTE The secondary filter must not be cleaned The engine must not be operated just with the secondary filter...

Page 157: ... changing 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 186 If concentrated Volvo Coolant VCS and clean water see page 182 is used the tab...

Page 158: ...ng the expansion tank pressure cap Shut down the engine Allow the engine to cool Turn the pressure cap slowly to release any pressure The coolant expansion tank is located under the engine hood on the right hand side of the machine Once the cooling system has cooled down the coolant level must be between the FULL MAX and LOW MIN marks in the coolant expansion tank 1 If the coolant level is near th...

Page 159: ... cooler fins with compressed air by blowing the dirt outwards from the side NOTE To facilitate the cooler fin cleaning the hydraulic oil cooler 2 and the AC unit evaporator 3 optional equipment can be removed 6 Loosen and remove the hydraulic oil cooler fixation screw 4 7 Carefully move the hydraulic oil cooler including the AC unit evaporator to the side 8 Use compressed air to clean the radiator...

Page 160: ...id damage to engine and cooling system different brands of coolant or corrosion protection must not be mixed 1 Shut down the engine 2 Open the engine hood 3 Slowly remove the cap from the expansion tank 1 and relieve the pressure in the cooling system 4 Top up coolant 5 Reinstall the cap on the expansion tank If the warning of high coolant temperature is shown on the display unit stop the engine i...

Page 161: ...attery gas contains hydrogen and is flammable and could explode Do not open a battery close to sources of fire such as open flames cigarettes or sparks Do not smoke near batteries as these give off flammable and explosive gases Make sure that metal objects for example tools rings and watch straps do not come into contact with the battery pole studs Make sure the protections are always installed ov...

Page 162: ...r eyes or any other sensitive body part rinse with plenty of water and seek immediate medical attention The battery is located on the left side of the cab To get access to the battery remove the left body by unscrewing the four screws not thoroughly then it will be easier to install The battery is maintenance free For longer storage periods disconnect the battery To remove the battery disconnect t...

Page 163: ... acid causes serious chemical burns Always wear personal protective gloves goggles and clothing when handling batteries WARNING Risk of chemical burns The battery 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 an...

Page 164: ...are clean well tightened and greased with Vaseline or similar Electrical welding NOTE Welding on the machine is not allowed If welding on the machine is needed it has to be approved by Volvo Construction Equipment Otherwise all additional welding is under customer responsibilities Any unauthorized welding could lead to a loss of warranty Service and maintenance Electrical system 163 ...

Page 165: ...ore unscrewing the plug 5 The oil level must reach the overflow point of the control opening 6 If the oil level is too low top up oil immediately to avoid damage on the travel gearbox for quality of oil refer to the table of fuels and lubricants page 179 Fill in oil up to the overflow point through the level control opening 7 Screw the level control plug 1 back in 8 Check the oil level after a few...

Page 166: ... undercarriage between the track pad and the track roller For steel tracks measure on both tracks the upper sag 6 For rubber tracks The track is correctly tensioned if the distance A is between 15 to 25 mm 0 59 to 0 98 in For steel tracks The track is correctly tensioned if the distance between the measurement tool and the track is between 15 to 25 mm 0 59 to 0 98 in 7 To reduce track slack on bot...

Page 167: ...er and steel tracks loosen the valve assembly 2 through one turn so the grease can drain off Tighten the valve unit when the track slack is correct 9 Adjust the other track unit in the same way 10 Run the track several times in forward and reverse and measure again if the track tension is correct after the adjustment NOTE For quality of grease please refer to the table of fuels and lubricants on p...

Page 168: ...ervoir filling device 2 Fill up the washer reservoir with washing fluid 3 Close the cap 1 of the washer reservoir filling device Front windscreen rails The front windscreen rails must be kept lubricated Start at one end of the rail and lubricate with grease all the way to the other end V1139344 1 V1090375 Service and maintenance Cab 167 ...

Page 169: ...equipment should be checked and the cabin filter should be changed every 1000 hours This work must only be done by authorised personnel in the dealer workshop Safety when handling refrigerant see page 140 168 Service and maintenance Air conditioning ...

Page 170: ...2 Clean the opening for tooth adapter locking device 3 Knock out the locking device with a hammer and the tool or other suitable drift 4 Remove tooth Installing tooth 1 Clean the front part of the tooth adapter and the hole for the locking device 2 Install the tooth so that the guide lugs fit in the tooth adapter recesses 3 Replace lock retainer B with a new part 4 Install the locking device so th...

Page 171: ... 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 V1066081 The locking device should be just below the scored line 170 Service and maintenance Bucket teeth ...

Page 172: ...nimum level and well below the maximum level A At 50 C hot machine the hydraulic oil level must be below the maximum level and well above the minimum level B If necessary fill hydraulic oil through filler neck on the hydraulic oil level sight glass For quality of hydraulic oil please refer to the table of fuels and lubricants on page 183 NOTE If the hydraulic system is filled with biodegradable hy...

Page 173: ... main purposes Add grease to the bearing to reduce friction between pin and bushing Replace old grease which may contain dirt The grease in the space inside the outer seal collects dirt and prevents dirt and also water from penetrating into the bearing Therefore grease the bearing until new clean grease is forced out through the outer seal For recommended grease see page 179 Wipe off grease nipple...

Page 174: ...hydraulic oil level Replace fuel filter Change the hydraulic oil Check coolant level Replace the hydraulic oil filter Change coolant Check the V belt tension V1087231 Clean filter element Check engine oil level V1087232 Change filter element Change engine oil V1087233 Replace cab ventilation filter Replace engine oil filter Change travel gear oil Grease nipple Service and maintenance Lubrication a...

Page 175: ...d 3000 operating hours according to Service Programme of the machine 6000 h 1000 h 500 h 250 h 50 h 10 h 6000 h 1000 h 500 h 250 h 50 h 10 h 1 1 1 2 1 1 1 1 1 2 1 1 1 1 2 1 V1137619 174 Service and maintenance Lubrication and service chart ...

Page 176: ... once after the first 50 hours then every 500 hours workshop job FIRST 50 hours inspection These inspections shall be performed by an authorized Volvo dealer Measure Page EVERY 250 hours After carrying out daily and 50 hours services Tracks check tension and condition 165 Track gearbox oil level check workshop job Measure Page EVERY 500 hours After carrying out daily 50 and 250 hours services Fan ...

Page 177: ...least once a year workshop job Exhaust manifold check for cracks gas leakage and loose mounting screws check at least once a year workshop job Air intake line check and replace if necessary check at least once a year workshop job Measure Page EVERY 1500 hours After carrying out daily 50 250 500 and 1000 hour services Injection nozzle pressure check workshop job Measure Page EVERY 2000 hours After ...

Page 178: ...RY 6000 hours After carrying out daily 50 250 500 1000 1500 2000 and 3000 hour services Coolant change or every fourth year with Volvo coolant VCS workshop job Service and maintenance Lubrication and service chart 177 ...

Page 179: ...ay freeze Ventilate well especially when the batteries are charged in a confined space When storing machines in extremely cold temperature remove batteries and parking them at room temperature Before parking remove the mud and the dirt from the tracks Demolition work Use fall protection over the cab against falling objects Low fuel quality Drain the sediments in fuel tank at shorter service interv...

Page 180: ...d meet our quality requirements The approval of Volvo is required if any other oil base quality e g biologically degradable oil is to be used NOTE BIO OIL and mineral oil must be disposed separately Mixing is prohibited Oil quality Viscosity under different ambient temperatures Engine Engine oil Volvo Ultra Diesel Engine Oil API CD CF CF 4 CI 4 Hydraulic system Hydraulic oil Acc to ISO 6743 4 HV o...

Page 181: ...ociety of Testing and Material SAE Society of Automotive Engineers ISO International Standardization Organization API American Petroleum Institute NOTE Use engine oil of type SAE 10W SAE 10W 30 or SAE 15W 40 if the engine is to be started under an ambient temperature of less than 0 C 32 F even if the daytime temperature rises up to 10 C 50 F 180 Specifications Recommended lubricants ...

Page 182: ...erval Volvo Ultra Diesel Engine Oil or VDS 3 or VDS 2 ACEA E7 or VDS 2 API CI 4 or VDS 2 EO N Premium plus 500 hour 250 hour 125 hour VDS 2 250 hour 125 hour 75 hour VDS ACEA E3 or ACEA E7 E5 E4 or API CI 4 CH 4 CG 4 125 hour 75 hour 50 hour Specifications Recommended lubricants 181 ...

Page 183: ... 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 184: ... 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 185: ...According to current EU legal requirements the sulphur content in the diesel fuel must not exceed 0 001 percent 10 ppm by weight For fuel specification according to the working temperature please contact a workshop authorized by Volvo Construction Equipment Biodiesel fuel Vegetable oils and or ester also referred to as bio diesel e g methyl esper or rapeseed RME are in some markets offered both as...

Page 186: ...fuel system impaired cold handling properties of the fuel limited storage life of the fuel which may lead to clogging of the fuel system if the machine has not been used over a long period Warranty The warranty does not apply to damage caused by an admixture of more than 7 of biodiesel fuel Specifications Fuel system 185 ...

Page 187: ...Cooling system total 8 l 2 1 US gal Engine oil including filter 10 2 l 2 7 US gal Hydraulic oil tank 50 l 13 2 US gal Hydraulic system total 63 l 16 6 US gal Travel gear 1 l 0 3 US gal Change intervals Please see lubrication and service chart on page 174 186 Specifications Service capacities and change intervals ...

Page 188: ... market 29 7 kW 40 4 PS 2200 rpm Engine power gross ISO 3046 1 for EU market SAE J1995 for US market 31 2 kW 42 5 PS 2200 rpm Max torque ISO 3046 1 155 Nm at 1600 rpm Number of cylinders 4 Cylinder bore 87 mm 3 43 in Stroke 110 mm 4 33 in Displacement 2615 cc Compression ratio 19 bar Firing sequence 1 3 4 2 Idling speed low 1100 rpm Idling speed high 2420 rpm or less Specifications Engine 187 ...

Page 189: ...302 Engine stop RE2502 Power supply engine RE3101 Main relay 1 RE3301 Starter motor RE3501 Working lights front V1139455 1 FU12 FU02 FU23 FU21 FU20 FU25 FU26 FU24 FU22 FU28 FU06 FU07 FU11 FU10 FU08 FU09 FU03 FU04 FU05 FU01 FU15 FU16 FU13 FU14 FU17 FU18 FU19 FU27 FU29 RE3501 RE3101 RE3508 RE2502 RE8705 RE3301 RE2302 2 Relays and fuses are located on the left side in the cab 1 under the driver s sea...

Page 190: ...peed switch quick attach switch FU14 3 A Cluster supply FU15 5 A Armrest switch safety pilot valve VECU FU16 10 A Motor controller supply FU17 3 A Keypad supply FU18 5 A VCADS caretrack supply FU19 5 A Orientation pressure switch FU20 5 A Travel alarm FU21 3 A 15 54 key status FU22 15 A Heater an switch heater fan motor AC motor FU23 5 A Refueling pump alternator FU24 10 A Wiper and washer FU25 5 ...

Page 191: ...Cab 190 Specifications Cab ...

Page 192: ... during real operating conditions at its intended use is less than 2 5 m s2 RMS root mean square 8 1 ft s2 acceleration according to ISO 8041 Whole body vibrations Emission of whole body vibration during real operating conditions at its intended use is according to the table below Typical operating conditions Vibration emission value 1 4aw eqx RMS Vibration emission value 1 4aw eqy RMS Vibration e...

Page 193: ...whole body vibration emission value declared by the manufacturer in accordance with European Standard is not intended to determine the whole body vibration exposure to the operator using this machine To ensure that the whole body vibration emission during machine use is kept to a minimum see Whole body vibrations Sound information Cab Sound pressure level LpA at operator position Measurement accor...

Page 194: ...Standby pressure 20 bar 290 psi Operating pressure HP pressure 260 bar 3771 psi Secondary pressure Boom cylinder 300 300 bar 4351 4351 psi Dipper arm cylinder 300 300 bar 4351 4351 psi Bucket cylinder 300 300 bar 4351 4351 psi Boom offset cylinder 350 350 bar 5076 5076 psi Accessory 220 220 bar 3191 3191 psi Specifications Hydraulic system 193 ...

Page 195: ...unterbalance valve fails If the traveling levers are released the machine will come to a stop after a few seconds Parking brake Place the bucket and the blade to the ground Slewing system Slewing system ECR50D Slewing ring with internal gearing and remote lubrication Slewing speed 6 3 s tr Brake system Parking brake Automatic interlocking of slewing superstructure spring friction brake Primary bra...

Page 196: ...bber tracks cab short arm pin on bucket 600 and 75 kg 165 lb operator 5010 kg 11045 lb Maximum machine weight Machine with 380 mm 14 96 in steel tracks cab long arm additional counterweight 120 kg 264 55 lb operator hydraulic breaker HB300 with quick attach OPG level 2 and several other options 5750 kg 12677 lb MuC without operator 4930 kg 10869 lb MuC Most usual configuration Specifications Machi...

Page 197: ...und pressure The ground pressure value is based on the MuC Most usual configuration weight of the machine ECR50D Version Ground pressure MuC with 400 mm 15 75 in rubber tracks 0 29 kg cm 196 Specifications Ground pressure ...

Page 198: ... in J Track length 2507 mm 98 70 in K 1748 mm 68 82 in L Overall width 1920 mm 75 59 in M Overall length 4602 mm 181 18 in 4420 mm 174 02 in N Overall height of engine hood 1678 mm 66 06 in O Minimum ground clearance 360 mm 14 17 in P Dozer blade hight 367 mm 14 45 in Q Shoe width 400 mm 15 75 in R Ground clearance to superstructure 666 mm 26 22 in S Front slew radius 2442 mm 96 14 in 2489 mm 97 9...

Page 199: ...84 mm 78 11 in U Overall height of superstructure with Cab 2582 mm 101 65 in W Overall width of superstructure with Cab 1603 mm 63 11 in X Tail slew radius 960 mm 37 79 in NOTE The machine specifications are given for information only and may be amended by the manufacturer at any time without prior notice 198 Specifications Dimensions ...

Page 200: ...3937 mm 154 99 in 4193 mm 165 08 in C Maximum digging depth with dozer blade lowered to ground 3400 mm 133 86 in 3800 mm 149 61 in D Maximum vertical wall digging depth 2416 mm 95 11 in 2791 mm 109 88 in E Maximum digging reach at ground level 5718 mm 225 12 in 6104 mm 240 31 in F Maximum digging reach 5908 mm 232 59 in 6288 mm 247 56 in Y1 922 mm 36 29 in Y2 726 mm 28 58 in Specifications Working...

Page 201: ...l tool for your business Volvo Hydraulic Thumbs GP bucket compatibility ECR50D X for direct fit mounting or with mechanical Volvo coupler Volvo ditch cleaning buckets fixed version 1300 mm 1500 mm 51 in 60 in ECR50D X X Volvo Tilt able ditch buckets Bolt on edge 1300 mm 51 in ECR50D available X Attachment brackets Volvo Quick Couplers Direct fit Volvo Quick Couplers Mechanical Hydraulic fully auto...

Page 202: ...et radius at the blade 696 mm 27 40 in Break out force at bucket blade 3612 daN 8120 lbf Break out force ISO SAE 3119 daN 7012 lbf Tear out force at bucket blade daN 2593 daN 5829 lbf 2177 daN 4896 lbf Tear out force ISO SAE 2490 daN 5598 lbf 2105 daN 4732 lbf Angle of rotation bucket 204 Specifications Digging forces 201 ...

Page 203: ...without attachment and without attachment bracket NOTE If handling is accomplished in lifting gear operation the weight of the attachments must be subtracted from the values stated in the table on level and firm ground with rubber tracks equipment during full rotation equipment parallel to the axis of the superstructure with a 75 kg 165 lb driver in the cab Lifting capacity decals inside cab 15687...

Page 204: ...Table Lifting capacities ECR50D V1139698 L F C P 260 bar H X C additional counterweight LB length of dipper arm Specifications Lifting capacities 203 ...

Page 205: ...Table Lifting capacities ECR50D with safety valve on blade V1139699 L F C P 260 bar H X FB C additional counterweight LB length of dipper arm 204 Specifications Lifting capacities ...

Page 206: ...Ready to use breaker Volvo hydraulic breaker Hydraulic hoses Hydraulic connectors 1 moil point ECR50D Different models available for all quick coupler provided by Volvo X X X X For further information about the Hydraulic breakers please refer to the separate attachment Operator Manuals Specifications Hammer 205 ...

Page 207: ...vice 1000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 1250 hours Type of service Signature and stamp Date Hours Service and maintenance Service 1500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 1750 hours Type of service Signature and stamp Date Hours Service and maintenance Service 2000 hours Type of service Signatur...

Page 208: ...amp Date Hours Service and maintenance Service 3500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 3750 hours Type of service Signature and stamp Date Hours Service and maintenance Service 4000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 4250 hours Type of service Signature and stamp Date Hours Service and maintenance S...

Page 209: ...e 5750 hours Type of service Signature and stamp Date Hours Service and maintenance Service 6000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 6250 hours Type of service Signature and stamp Date Hours Service and maintenance Service 6500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 6750 hours Type of service Signature a...

Page 210: ...e 8250 hours Type of service Signature and stamp Date Hours Service and maintenance Service 8500 hours Type of service Signature and stamp Date Hours Service and maintenance Service 8750 hours Type of service Signature and stamp Date Hours Service and maintenance Service 9000 hours Type of service Signature and stamp Date Hours Service and maintenance Service 9250 hours Type of service Signature a...

Page 211: ... 9750 hours Type of service Signature and stamp Date Hours Service and maintenance Service 10000 hours Type of service Signature and stamp Date Hours Service and maintenance 210 Specifications Service history ...

Page 212: ...mensions 197 Disconnecting with pivot pins 113 Display panel 31 Display unit 28 Door 60 E Eco driving 88 Electrical system 9 160 188 Electrical welding 163 Emergency exit 61 Engine 9 151 187 Engine air cleaner 154 Engine oil 181 Engine oil level checking 151 Entering leaving and climbing the machine 136 Environmental requirements 9 Equipment 11 EU conformity certificate 18 F Fire extinguisher loca...

Page 213: ...change intervals186 Service history 144 206 Service points 149 Service position 132 Service Programme 145 Signalling diagram 128 Slewing system 12 194 Special hydraulics 109 Starting engine 74 Stopping 76 Symbol key 173 T Theft protection 40 Thumb 114 Thumb attachment 114 Tool kit 14 Touch up painting 147 Track unit 165 Track unit checking tension 165 Tracks 122 Transmission 194 Transporting machi...

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Summary of Contents for ECR50D

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Volvo ECR50D, Operator'S Manual, Page: 175 / 213

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Summary of Contents for ECR50D

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