Excavator Operator Manual

EC700B OPERATOR'S MANUAL
Foreword
This Operator Manual is intended as a guide for the correct Table of contents
use and maintenance of the machine. Therefore, study it
carefully before starting and operating the machine, or before
carrying out any preventive maintenance.
Keep the manual in the cab so that it is always at hand. Re-
place it immediately, if it is lost.
Presentation
The manual describes the applications for which the machine
primarily is intended and is written to apply for all markets. We
therefore ask you to disregard the sections which are not ap-
plicable to your machine or to the work for which you use your Instrument panels
machine.
Many hours are spent on design and production to make a

machine that is as efficient and safe as possible. The acci-
dents which occur in spite of this, are mostly caused by the Other controls
human factor. A safety conscious person and a well main-
tained machine make a safe, efficient and profitable combina-
tion. Therefore, read the safety instructions and follow
them.
We continually strive to improve our products and to make Operating instructions
them more efficient through changes to their design. We re-
tain the right to this without committing ourselves to introduc-
ing these improvements on products which have already
been delivered. We also retain the right to change data and
equipment, as well as instructions for service and other main- Operating techniques
tenance measures without prior notice.
Safety regulations
It is the operator’s obligation to know and follow the applica-
ble national and local safety regulations. The safety instruc-
Safety when servicing
tions in this manual only apply to cases when there are no
national or local regulations.
Service and maintenance
WARNING!
The symbol above appears at various points in the
manual together with a warning text. It means: Specifications
Warning, be alert! Your safety is involved! It is the
obligation of the operator to make sure that all warning
decals are in place on the machine and that they are
readable. Accidents may otherwise occur.
Alphabetical index
Get to know the capacity and limits of your
machine!
Ref.No. VOE21A1001541
The original language is English
Printed in Korea 2005.11
Foreword
2 Identification numbers
Identification numbers
Make a note below of the identification numbers of the machine and its components. Always state the number
when contacting the manufacturer and when ordering spare parts.
Volvo Construction Equipment Korea Ltd.

Manufacturer:
1,Guehyun-Dong, Changwon-City, Kyungnam, Korea
Machine PIN
(Serial number)
Engine
Swing motor
Travel motor
Please send any comments regarding the Operator's Manual to om@volvo.com

Table of contents
3
Table of contents
Foreword ................................................................... 1
Identification numbers ............................................................ 2
Table of contents...................................................... 3
Presentation.............................................................. 5
Machine view.......................................................................... 8
CE marking, EMC directive .................................................... 9
Communication equipment, installation................................ 10
Product plates....................................................................... 11
Information and warning decals............................................ 12
The USA federal clean air act............................................... 19
Instrument panels .................................................. 23
Front instrument panel (IECU).............................................. 24
Right instrument panel.......................................................... 35
Upper instrument panel ........................................................ 38
Left instrument panel ............................................................ 44
Rear instrument panel .......................................................... 49
Other controls......................................................... 53
Levers and pedals ................................................................ 53
Optional parts ....................................................................... 57
Control lock-out system ........................................................ 59
Operator comfort .................................................................. 60
Operating instructions ........................................... 69
Running-in instructions ......................................................... 69
Safety rules when operating ................................................. 70
Working within dangerous area ............................................ 72
Measures before operating................................................... 74
Starting ................................................................................. 76
Stopping and parking............................................................ 78
Transporting the machine..................................................... 80
Lifting the machine ............................................................... 87
Towing the machine ............................................................. 88
Operating techniques ............................................ 89
Rules for digging................................................................... 90
Whole-body vibrations .......................................................... 92
Working on slopes ................................................................ 94
Escaping from swampy ground ............................................ 95
Working in cold weather ....................................................... 96
Working with bucket ............................................................. 97
Working with long range attachment .................................... 99
Hose rupture valves (optional equipment).......................... 100
Boom float position (optional equipment) ........................... 101
Counterweight .................................................................... 102
Adjustable track gauge ....................................................... 107
Selecting track shoes ......................................................... 108
Lifting objects...................................................................... 109
Hydraulic hammer (optional equipment)............................. 110
Signalling diagram .............................................................. 113
Table of contents
4
Safety when servicing ..........................................117

Service position .................................................................. 117
Entering / leaving / climbing the machine ........................... 118
Before service, read ........................................................... 119
Fire prevention.................................................................... 121
Handling hazardous materials ............................................ 123
Service and maintenance.....................................127
Service points ..................................................................... 130
Engine ................................................................................ 131
Fuel system ........................................................................ 133
Intercooler........................................................................... 136
Turbocharger ...................................................................... 136
Air cleaner .......................................................................... 137
Dry type precleaner (optional equipment) .......................... 138
Cooling system ................................................................... 140
Electrical system................................................................. 143
Air conditioner..................................................................... 146
Hydraulic system ................................................................ 147
Swing drive unit .................................................................. 151
Swing gear and bath........................................................... 152
Track drive unit ................................................................... 153
Accumulator, handling ........................................................ 154
Track unit............................................................................ 155
Bucket................................................................................. 157
Excavator unit, greasing ..................................................... 158
Lubrication .......................................................................... 160
Lubrication and service chart.............................................. 161
Periodic replacement of critical parts for safety .................. 164
Specifications........................................................165
Recommended lubricants................................................... 165
Recommended grease ....................................................... 166
Service capacities and intervals ......................................... 167
Engine, specifications......................................................... 169
Electrical system, specifications ......................................... 170
Cab, specifications ............................................................. 171
Hydraulic system, specifications......................................... 172
Total machine, dimensions ................................................ 174
Bucket & Arm combination ................................................. 175
Disassembled parts, dimension and weight ....................... 177
Digging forces with direct fit bucket .................................... 179
Working ranges .................................................................. 180
Lifting capacity.................................................................... 181
Service history .................................................................... 188
Alphabetical index ................................................193
Presentation
5
Presentation
S82382
Intended use
The machine is intended to be used under normal conditions for
the applications described in this manual. If it is used for other pur-
poses or in potentially dangerous environments, for example ex-
plosive atmosphere or areas with dust containing asbestos, etc.,
special safety regulations must be followed and the machine be
equipped for such use. Contact the manufacturer / dealer for fur-
ther information.
Engine
The engine is a straight six-cylinder, four stroke, direct injection
diesel with 16 liter cylinder volume, turbo charged, intercooled and
electronically controlled fuel injection, EMS2 (Engine Management
System) with a cast iron block and cylinder head, Volvo engine.
Electrical system
The electrical system consists of engine starting system, charging
system, machine monitoring system, engine/ pump control system
and air conditioning system.
Engine speed is controlled by a rotary switch that incrementally
changes rpm, and an auto idle system that automatically engages
low idle when the machine is not operated for 5 seconds or more.
Engine condition can be checked via the V-ECU (Vehicle Electron-
ic Control Unit) by the data connection between EMS (Engine
Management System) and V-ECU.
IECU (Instrument Electronic Control Unit) consists of central warn-
ing lamp, two analog gauges, 21 indicators, MCD (Message Cen-
ter Display), and four push buttons. IECU is installed inside the cab
and displays the vehicle information for the operator.
Presentation
6
Track motor and gearbox

The track motor is a variable axial piston motor that consists of a
housing, a rotary group and a port plate. The housing contains the
swash angle control screw. The rotary group consists of the cylin-
ders and the pistons. The port plate consists of the counterbalance
valve, the check valves, the relief valves and the displacement
changeover valve. Track motor also houses the spring applied, hy-
draulically released parking brake assembly.
The gearbox has a three-stage planetary mechanism has three
sets of sun gears, planetary gears and pinion gears, driven by the
splined output shaft of the track motor mounted directly to the
gearbox.
Swing motor and gearbox

The swing motor is a fixed axial piston motor. The rotary group
consists of a cylinder block and nine pistons located in the cylinder.
The cover section has relief valves, an anti-cavitation valves and
anti-rebound valves. The housing has a delay valve and a disk
type brake.
The gearbox is composed of the sun gear, the planetary gear, the
pinion gear and the housing. The power supplied to the output
shaft of the swing motor reduces motor speed through the sun
gear and the planetary gear, developing high torque that is trans-
mitted to the pinion gear.
Cab
The cab has a heating and ventilation system with defrosting from
front and rear windows. Air conditioning is available as an optional
equipment. The cab have two emergency exits, the door and the
rear window.
Anti-theft device (optional equipment)

An installed anti-theft device makes it more difficult to steal the ma-
chine. Volvo CE supplies anti-theft devices as optional equipment.
If your machine is not yet equipped with one, check the possibili-
ties of having such a device installed by your dealer.
FOPS and FOG

The cab is approved as a part of protective structure according to
FOPS and FOG standards. FOPS is an abbreviation of Falling Ob-
ject Protective Structure (roof protection) and FOG is an abbrevia-
tion of Falling Object Guard.
Never carry out any unauthorized alterations to the cab, e.g. low-
ering the roof height, drilling, welding on brackets for fire extin-
guisher, 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 is important that all parties concerned are aware of these regu-
lations.
Presentation
7
Hydraulic pump
The hydraulic pump assembly consists of two pumps connected
by a splined coupling. The two pumps are driven simultaneously
as the engine rotation is transmitted to the front drive shaft.
The pump consist of rotary group, swash plate group and valve
block group.
The displacement of the pump is controlled by the regulator, and
engine output power is effectively utilized by the proportional sole-
noid valve.
Main control valve

The control valve consists of two 5-spool blocks and an intermedi-
ate block connected by screws. They contain six main spools for
digging units, three spools for conflux and straight travel, a spool
for the option unit, a main relief valve, port relief valves, holding
valves and check valves. These are remotely controlled by pilot
valves of hydraulic system.
Modifications
Modifications to this machine including the use of unauthorized at-
tachments, accessories, assemblies or parts may affect the integ-
rity of the machine and/or the ability of the machine to perform as
designed. Persons or organizations making unapproved modifica-
tions assume all liability arising from or related to the modification,
including any adverse affect on the machine.
No modifications of any kind should be made to this product unless
the specific modification has been officially approved in writing by
Volvo Construction Equipment. Volvo Construction Equipment re-
serves the right to reject any and all warranty claims which arise
from or are related to unauthorized modifications.
Modifications are officially approved if at least one of the following
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 Equip-
ment.
Presentation
8 Machine view
Machine view
11 10 9
12
8 7
13 6
5
2
14
1
15
16
4 3
17
18
19
20
21 S83459
22 23 24
1 Dipper arm cylinder 13 Radiator and Charged air cooler

2 Boom 14 Air cleaner
3 Boom cylinder 15 Oil cooler
4 Turning joint 16 Track motor and gearbox
5 Operator cab 17 Fuel tank
6 Swing motor and gearbox 18 Upper roller
7 Battery 19 Bottom roller
8 Hydraulic tank 20 Idler
9 Main control valve 21 Bucket
10 Muffler 22 Link
11 Engine 23 Dipper arm
12 Counterweight 24 Bucket cylinder
Presentation
CE marking, EMC directive 9
CE marking, EMC directive

CE marking
(Declaration of Conformity)
(Only applies to machines marketed within the EU/EEA.)
This machine is CE marked. This means that when delivered the
machine meets the applicable "Essential Health and Safety Re-
quirements", which are given in the EU Machinery Safety Direc-
tive, 98/37/EC.
Any person carrying out changes that affect the safety of the ma-
chine, is also responsible for the same.
As proof that the requirements are met, the machine is supplied
with an EU Declaration 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 doc-
ument, 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 manual, safety must at all times and in each
separate case be maintained. The person carrying out such action
is also responsible for the action which, in some cases, may re-
quire a new CE marking and the issue of a new EU Declaration of
Conformity.
EU EMC Directive
The electronic equipment of the machine may in some cases
cause interference to other electronic equipment, or suffer from ex-
ternal electromagnetic interference, which may constitute safety
risks.
The EU EMC directive about "Electromagnetic compatibility", 89/
336/EEC, provides a general description of what demands can be
made on the machine out 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 electro-
magnetic interference. The CE marking of the machine and the
declaration of conformity also cover the EMC directive.
If other electronic equipment is fitted to this machine, the equip-
ment must be CE marked and tested on the machine with regard
to electromagnetic interference.
Presentation
10 Communication equipment, installation
Communication equipment,
installation
IMPORTANT! All installation of optional electronic communi-
cation equipment must be performed by trained profession-
als and in accordance with the Volvo CE instructions.
Protection against electromagnetic interference

This machine has been tested in accordance with EU directive 89/
336/EEC governing electromagnetic interference. It is therefore
very important that all non-approved electronic accessories, such
as communication equipment, should be tested before installation
and use, since they can cause interference to the electronic sys-
tems of the machine.
Mobile telephones
To obtain the best functionality, mobile telephones should be per-
manently installed in the electrical system of the machine, with a
permanent aerial fixed on the cab and installed as advised by the
manufacturer. If a portable mobile telephone is used, note that it
can constantly transmit information to its base station, even when
the telephone is not used. For this reason, it should not be placed
beside electronic equipment in the machine, such as directly on a
control panel etc.
Guidelines
The following guidelines must be followed during installation:
■ The antenna placement must be chosen to give good adapta-
tion 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 removed. Protect the mating surfaces against corro-
sion after installation to maintain good galvanic contact.
■ Remember to separate interfering and interfered cables physi-
cally. Interfering cables consist of the communication equip-
ment’s supply cables and antenna cable. Interfered cables are
those which are connected to electronic devices in the ma-
chine. Install the cables as close as possible to earthed
(grounded) sheet metal surfaces, since the sheet metal has a
shielding effect.
Presentation
Product plates 11
Product plates
The illustration shows where the plates are placed on the machine
and below follow a description of them.
When ordering spare parts and in all telephone enquiries or corre-
spondence the model designation and Product Identification Num-
ber (PIN) must always be quoted.
3
30
20
350
2
S83413
1 Product plate
This plate with Product Identification Number, PIN, for the com-
plete machine indicates the model designation, serial number and
when applicable, machine weight, engine power, manufacturing
year and CE approval. The plate is positioned on the right side of
the upper frame.
2 Engine
The engine type designation, part and serial numbers are stamped
on the side of valve cover.
3 Bucket
This nameplate is attached on the top of the bucket and indicates
the bucket model order number, serial number, bucket part
number, rated capacity, weight, cutting width, tooth part number
and adapter part number.
Presentation
12 Information and warning decals
Information and warning decals

The operator should know and pay attention to the information and warning decals which are positioned on the
machine. All decals are not installed on all machines, as they are market and machine dependent. The decals
must be kept free from dirt, so that they can be read and understood. If they have been lost or are illegible, they
must be replaced immediately. The part number (order number) is given on the respective decals and in the Parts
Catalogue.
1
28 29 8 30
25
4
25
6,27
11 31 9 10
14 18 25 36 24
16
19
38
33
15 37
35 44 1
20 3 39 26 7 43
12 22 41 22
32
13
15 35
2 40 21 17,34 42 S83411
Presentation
Information and warning decals 13
S80598 S80606
1 WARNING! Read the Operator’s manual 2 WARNING! Do not start the engine
S82335
S80720
3 WARNING! Safety locking 4 WARNING! Do not step or walk
S80605A S80715
5 WARNING! Rotating parts 6 WARNING! Hot and pressurized coolant
o
45
CHECK THE EXISTING CONTROL PATTERN TYPE BEFORE MOVING ANY

OF THE CONTROL.
CONTROL PATTERN SELECTOR LEVER IS LOCATED IN AIR CLEANER
ROOM
READ OPERATOR’S MANUAL AND UNDERSTAND CONTROL PATTERN.
S86512
S86511
7 WARNING! Pattern change (optional) 8 WARNING! Boom float position

Presentation
S83460 S80602A
9 WARNING! Operating the optional attachment 10 WARNING! High voltage
S80607 S82023
11 WARNING! Do not smoke when fueling 12 WARNING! Removal counterweight device
! WARNING
S80718 S80608
13 WARNING! Handling accumulator 14 WARNING! Risk of fire when fueling
! WARNING
S80579A S80603
15 WARNING! Excavator’s working area 16 WARNING! Risk of slipping or falling

Presentation
S80721
S80605
17 WARNING! Battery 18 WARNING! Rotating and / or hot parts
S86583
S80601
19 WARNING! Locking the front window 20 WARNING! Cab door window breakage
S80599
S80596
21 WARNING! Do not unscrew the recoil spring 22 WARNING! Excavator working area
! WARNING
S80471 S86582
23 WARNING! Read the Operator’s manual be- 24 WARNING! Risk of visual distortion through roof
fore operating the attachment bracket (quickfit, window
optional, not applicable)
Presentation
S80717 S86513
25 Lifting point 26 Auto / Manual switches. See page 47.
EC700B
kg mm
km/hr mm
o
mm
mm
kg/cm 2
mm
mm mm
ps/rpm mm
rpm
S83480
S86514
27 Coolant information 28 Machine specifications (Optional)
12
11
10
360 9
LD 8
6.6m Kg
7
5 X
11300kg Z2
4
Z1 0
m
-1
-2
-3
Z3 -4
-5
-6
-7
X(m) 0 1 2 3 4 5 6 7 8 9 10 11 12
Kg
X(m) > 3.0m 4.5m 6.0m 7.5m 9.0m 10.5m

Z2 - 28970 19530 17000 13220 -
LD=
Z1 29170 31670 22160 16050 12660 -
2.90m
Z3 35990 20730 22230 - - -
S83461 S83481
29 Thumb operation (Optional) 30 Lifting capacity

Presentation
S81209 S80716A
31 Operating the attachments 32 Position of checking hydraulic oil level
S82035
S83497
33 Machine lifting (optional) 34 Battery position
S81230A S83482A
35 Notice attachment 36 Noise level, internal cabin noise (optional)
250
S86518 S82300C
37 Greasing point 38 Optional pedal operation (optional)

Presentation
3000h
2000h
1000h
500h
250h
50h
10h
10h
dB 50h
250h
500h
1000h
2000h
3000h
S86555 S83483
39 Noise level, outdoor noise (optional) 40 Lubrication chart
S80954 S86584
41 Emergency exit 42 Attaching point for lashing / tying down
68.3
4.29 S86520A
43 Machine weight and width (optional)

Presentation
The USA federal clean air act 19
The USA federal clean air act

The Federal Clean Air Act Section 203 (a) (3) prohibits the removal
of air pollution control devices or the modification of an EPA certi-
fied non road engine to a non certified configuration.
The Federal regulations implementing the Clean Air Act for non
road engines, 40 C.F.R. Section 89.1003(a)(3)(i) reads as follows:
The following acts and the causing thereof are prohibited:

For a person to remove or render inoperative a device or ele-
ment of design installed on or in a non-road engine vehicle or
equipment in compliance with regulations under this part pri-
or to its sale and delivery to the ultimate purchaser or for a
person knowingly to remove or render inoperative such a de-
vice or element of design after the sale and delivery to the ul-
timate purchaser.
The law provides a penalty of up to $2,500 for each violation.
An example of a prohibited modifications is the recalibration of the

fuel system so that the engine will exceed the certified horsepower
or torque.
You should not make a change to an EPA-certified non-road en-

gine that would result in an engine that does not match the engine
configuration certified to meet Federal Standards.
Customer Assistance
Volvo CE wishes to help assure that the Emission Control System
Warranty is properly administered. In event that you do not receive
the warranty service to which you believe you are entitled under
the Emission Control System Warranty, you should contact your
nearest Volvo CE Regional office for assistance.
Presentation
20 The USA federal clean air act
Normal non-road engine use

The Maintenance Instructions are based on the assumption that
this conventional machine will be used as designated in the Oper-
ator’s Manual and operated only with the specified fuel and lubri-
cation oils.
Non-road engine maintenance

The non-road engine is of conventional design and any local deal-
er may perform the necessary non-road engine emission control
maintenance defined in this manual.
Volvo CE recommends that the purchaser use the service pro-

gramme for the non-road engine, known as Preventive Mainte-
nance, including the recommended engine emission control
maintenance.
In order to document that the proper regular maintenance has

been performed on the non-road engine, Volvo CE recommends
that the owner keep all records and receipts of such maintenance.
These records and receipts should be transferred to each subse-
quent purchaser of the non-road engine.
Service performed by your local dealer

Your local dealer is best qualified to give you good, dependable
service since he has trained service technicians and is equipped
with genuine original manufacturer’s parts and special tools, as
well as the latest technical publications. Discuss your servicing
and maintenance requirements with your local dealer. He can tailor
a maintenance program for your needs.
For regular scheduled service or maintenance, it is advisable to

contact your local dealer in advance to arrange for an appointment
to ensure availability of the correct equipment and service techni-
cian to work on your machine. This will aid your local dealer in ef-
forts to decrease service time on your machine.
Presentation
The USA federal clean air act 21
Preventive maintenance
To retain the dependability, noise level and exhaust emission con-
trol performance originally built into your conventional non-road
engine, it is essential that the non-road engine receive periodic
service, inspections, adjustments and maintenance.
Fuel system
Fuel Recommendations:
The fuel used must be clean, completely distilled, stable and non-
corrosive. Distillation range, cetane level and sulphur content are
most important when selecting fuel for optimum combustion and
minimum wear.
Engine working conditions and ambient temperature influence the

selection of the fuel with respect to cold handling properties and
cetane levels.
In cold weather conditions, below 32 °F (0 °C), the use of lighter

distillate or higher cetane level fuel are recommended (final boiling
point max. 660 °F (349 °C) and cetane min 45).
To avoid excessive deposit formation and to minimize the emis-

sions of sulphur dioxide into the ambient air, the sulphur content of
the fuel should be the lowest available. The diesel fuels recom-
mended for use in Volvo engines should meet ASTM designation:
D975 No. ID (C-B) or No. 2D (T-T); with a cetane level above 42
and sulphur content not exceeding 0.5 percent by weight.
Check for fuel leaks (with the engine running at fast idle):
■ Visually check unions and hose connections.
Check the condition of the fuel hoses for:

■ Aging
■ Cracks
■ Blisters
■ Scuffing
Check the condition of the fuel tank:

■ Drain water condensation
■ Check for cracks
■ Check for leaks
■ Check the mounting
Check the turbocharger:

■ Visually check for leaks in the intake hoses and exhaust pipe of
the turbocharger.
Presentation
22
Instrument panels
23
Instrument panels
WARNING!
Do not operate the machine until you are thoroughly
familiar with the position and function of the various
instruments and operating controls. Read the Operator’s
Manual thoroughly - Your safety is involved.
2
4
S86211A
1 2 3
4 5 6
1 Front instrument panel (IECU)
2 Right instrument panel
3 Upper instrument panel

4 Left instrument panel
5 Rear instrument panel

Instrument panels
Front instrument panel (IECU)

It is possible to prevent the machine from serious damages by tak-
ing action in time. Therefore, look now and then at the front instru-
ment panel where the operator is provided with information.
When the ignition key is turned to the running position, the lamps
mentioned below should light up for three seconds and the buzzer
sounds twice at the same time. The lamps for the battery charge
and engine oil pressure will remain illuminated until the engine is
started.
If red control lamps light up, stop the machine immediately!
If amber warning lamps light up, measures may be required
depending on the function concerned.
The remaining lamps indicate that the respective function is en-
gaged or activated.
3
2
4-10
11-17
18-24
25
26
S86015
1 Central warning lamp 14 Air cleaner clogging warning indicator

2 Engine coolant temperature gauge 15 Air preheating indicator
3 Fuel level gauge 16 Hydraulic oil temperature warming indicator
4 Parking brake indicator (not applicable) 17 Hydraulic oil filter clogging indicator (not applicable)
5 Brake oil pressure warning indicator (not applicable) 18 Battery charge warning indicator
6 Low steering pressure indicator (not applicable) 19 Attachment bracket (quickfit) indicator (not applicable)
7 Axle lock indicator (not applicable) 20 Overload warning indicator (optional equipment)
8 Alignment indicator (not applicable) 21 Boost indicator
9 High beam indicator (not applicable) 22 Float operation indicator (optional equipment)
10 Left / Right turn signal indicator (not applicable) 23 Hammer operation indicator (optional equipment)
11 Engine oil pressure warning indicator 24 Shear operation indicator (optional equipment)
12 Engine coolant temperature warning indicator 25 MCD (Message Center Display)
13 Coolant level indicator 26 Scroll / Confirm buttons
Instrument panels
Front instrument panel (IECU) 25
1 Central warning lamp

The central warning lamp blinks and the buzzer sounds at the
same time when a fault occurs in either of the following functions.
S86016 Alarm : buzzer sounds periodically
– Attachment bracket (quickfit), open
– Engine oil pressure, low
– Engine coolant temperature, high
– Overload
Caution : buzzer sounds one time
– Air cleaner clogging
– Coolant level, low
– Battery charge
– Hydraulic oil temperature, high
NOTE! If the lamp flashes while operating, stop the machine
immediately and investigate the cause.
2 Engine coolant temperature gauge

The gauge shows the temperature of the engine coolant. The
more black bars, the higher is the temperature. If the temperature
becomes abnormally high, the warning lamp will light up and the
buzzer will sound.
S86017
If this happens, turn off the engine immediately and investi-
gate the cause.
3 Fuel level gauge

The gauge shows the level in the fuel tank. When the tank is full,
all bars are black. When only one section remains, it starts to flash.
Refuel the machine immediately in order to avoid air entering into
the fuel system. Always refill the fuel tank at the end of every work
S86018 day.
If the tank has been run empty, see page 135. For the capacity of
the fuel tank, see page 167.
4-10 Not used
11 Engine oil pressure warning indicator

The lamp is alight, the central warning lamp blinks and the buzzer
sounds, if the oil pressure in the engine becomes too low.
S86026 If this happens, turn off the engine immediately and investi-
gate the cause.
12 Engine coolant temperature warning indicator

sounds, if the engine coolant temperature becomes too high.
gate the cause.
Instrument panels
13 Coolant level indicator

sounds, if the coolant level becomes too low.
S86028
14 Air cleaner clogging warning indicator

sounds, if the air cleaner becomes clogged.
S86029
If this happens, clean or change the cleaner, see page 137.
15 Air preheating indicator

The lamp is alight when the preheating is activated, see page 76.
S86030
16 Hydraulic oil temperature warning indicator

sounds, if the hydraulic oil temperature becomes too high.
If this happens, stop the work immediately and investigate the
S86031
cause.
17 Not used
18 Battery charge warning indicator

sounds, if the charging system malfunctions.
gate the cause. Otherwise, the batteries may be damaged.
19 Attachment bracket (quickfit) indicator (not

applicable)
S86034 begins to sound when the attachment bracket is opened, provided
that the two attachment bracket switches on the left instrument
panel and the upper instrument panel are pressed simultaneously.
WARNING!
If the red warning lamp lights up on the front instrument
panel when opening the attachment bracket, while the
bucket is still attached to the bracket, the excavator
equipment should not be operated. Which cause a sudden
falling of bucket or fatal injuries.
Instrument panels
20 Overload warning indicator (optional equip-

ment)
S86039
WARNING!
If the overload warning lamp lights up, stop the lifting
operation and reduce the load. Otherwise, serious
accidents can happen.
begins to sound, if the attachment becomes overloaded, provided
that the switch on the right instrument panel is pressed down.
21 Boost indicator
The lamp is alight when the power boost function has been select-
ed on the right control lever and the switch on the upper instrument
S86040 panel should be for power boost function at the same time.
22 Float operation indicator (optional equipment)

The lamp is alight when the float function has been selected on the
right control lever.
S86041
23 Hammer indicator (optional equipment)

The lamp is alight when the hammer function on the upper instru-
ment panel is selected.
S86036
24 Shear selecting indicator (optional equipment)

The lamp is alight when the shear function on the upper instrument
panel is selected.
S86042
25 MCD (Message Center Display)

Start up screen
When the ignition key is turned to running position, the start up
screen is shown. Five dots light up one by one and the machine
EC700B model is shown during maximum two seconds. Let all dots light up
S86301 before turning the ignition key to starting position.
Shut down screen

When the ignition key is turned to stop position, the shut down
screen is shown. Five dots are extinguished one by one and the
machine model is shown during maximum three seconds.
EC700B
S86302
Instrument panels
26 Scroll / Confirm buttons

Use the three arrow buttons to scroll between the screens and the
S86038
confirm button to confirm a setup.
The confirm button is also used either to turn off the buzzer if an
error code is shown, or to confirm the error message.
While the start up screen is shown, the buttons are locked.
Error messages
For some errors that may occur while operating, an error message
is shown on the display unit on the front instrument panel. At the
same time, a buzzer sounds and if the error is serious, the central
warning lamp is alight. The buzzer is shut off by pushing the con-
firm button once and the error message is removed by two pushes.
S86044 Each message includes a code, which is important to note, before
contacting the workshop.
Contact the workshop if the following error messages appear.
Note the code first!
Engine
128 PID 105 3 128 PID 45 4 128 PID 94 0

S86045A S86048A
S86180
128 PID 97 0 128 PID 98 0 128 PID 153 0

S86180A S86181 S86045B
Hydraulic
187 PPID 1190 3 187 PPID 1191 3 187 PPID 1114 3

S86052A S86052C S86052D
Electric
187 SID 251 0

S86047A
ECU
ECU ECU ECU

187 SID 254 12 187 no signal 128 SID 254 12
S86050A S86050B S86050C
ECU ECU
ECU ECU
187 SID 231 12 187 SID 250 12
S86049A S86049B
Instrument panels
Operator information
After the start up screen has been extinguished, this default screen
showing the engine speed appears on MCD (Message Center Dis-
play) (A).
S86058
Screen 1 Default screen

After starting, this default is shown on MCD (Message Center Dis-
2000 RPM G1 play).
Engine speed and selected mode are displayed at first line.
13 : 24
Time is displayed at second line. The displayed time format is se-
S86059 lectable on other screen. see page 32.
When the optional equipment for X1 is equipped and hammer or

2000 RPM G1 shear is selected, the X1 and flow are displayed.
X1 :
13 : 24 120 L
S86574
Normal operating screen
Screen 1 Screen 1.1 Screen 1.2
2000 RPM G1 24 13 : 24
30 min
13 : 24 24. 04. 2003
Screen 2 Screen 2.1 Screen 2.2
100 L 110 L
1111 hour
120 L
X1 100 L X1 140 L X1100 L 120 L
Screen 3
111.1 H
Screen 4 Screen 4.1
28.2 V
Screen 5
EC700B
S.No : 12345
Screen 6 Screen 6-1
No Error
128 PID 102 3

1) No error 2) Only 1 error
Screen 6-2 Screen 6-2.1
128 PID 102 3 187 PPID 1191 3

3) Several errors
S86303
Instrument panels
Screen 1.1 Press arrow right to go to screen 1.1 on the default screen 1.
– Time and date (the symbol shows if the 12 or 24 hours format
24 13 : 24 is selected). For changing the format, see page 32.
24. 04. 2003

S86061
Press arrow right to go to screen 1.2.
Screen 1.2
– This is shown only when code lock is set. see page 33.
30 min
S86062
Screen 2 Press arrow down to go to screen 2.

– This is shown when optional equipment for X1 is attached.
1111 hour
X1 100 L
S86190

– Engine operating lap time since last reset time.
111.1 H – Stop watch (reset by pressing the confirm button for more than
one second)
S86191

– Battery voltage is shown
28.2 V
S86065
Screen 4.1 Press arrow right to go to screen 4.1.

– Contrast (changed by pressing arrow) down (darker) or up
(lighter)
– Keep the setting by pressing the confirm button for more than
one second.
S86066
Screen 5
Press arrow down to go to screen 5.
– Model name and serial number are shown
EC700B
S.No : 12345
S86304
Instrument panels
Screen 6 Press arrow down to go to screen 6, 6-1 or 6-2.

– Screen 6 is shown for no error
No Error
S86069
– Screen 6-1 is shown for only 1 error

Screen 6-1
128 PID 102 3

S86070
– Screen 6-2 is shown for several errors more than two.

Screen 6-2
128 PID 102 3

S86071
Press arrow right to go to screen 6-2.1

Screen 6-2.1
Press arrow right again and again to go to other error screens.
187 PPID 1191 3

S86072
Instrument panels
Setup time and date

24
24
S86078
24
DD-MM-YYYY
S86077 – Time and date setup. Interrupt the setup by pressing the con-
firm button for more than one second.
Press arrow up and arrow down at the same time for more than
one second to get to the changing mode.
24
S86079
Change the time setting (24 or 12 hours format)

– When the symbol flashes, press arrow up or arrow down to get
the other format.
Press arrow right to change the hours.
Change the hours
– When the hour flashes, press arrow up or arrow down to
change hour.
Press arrow right to change the minutes.
Change the minute
– When the minute flashes, press arrow up or arrow down to
change minute.
Press arrow right to change date.
DD-MM-YYYY
S86080
Change the date setting (DD-MM-YYYY, MM-DD-YYYY, YYYY-

MM-DD)
– When the date flashes, press arrow up to change the date set-
ting.
Press arrow right to change date, month or year.
Change the date, month or year
– When the first group of digits flashes, press arrow up or arrow
down to make a change.
– Press arrow right to go to the next group of digits. Change with
arrow up or down or press right to go to the next.
– Confirm by pressing the confirm button for more than one sec-
ond.
Instrument panels
Code lock (optional equipment)

01 2 3 The machine can be equipped with theft protection in the form of a
code lock which prevents start of the machine without the correct
four-digit code.
NOTE! Do not forget the code. It can only be programmed and
01 2 3 changed via VCADS Pro. If you forget the code, contact your
* dealer.
Unlocking the code lock.
01 2 3 – Enter the four-digit code (consists of the digits 0, 1, 2 and 3) and
press the confirm button for more than one second.
** If it is correct, the start up screen is shown.
If it is incorrect, the first screen is shown again. After four, failed at-
01 2 3 tempts to enter the correct code, the system will be locked for ten
*** minutes and the first screen is still shown if the ignition key is in
running position. After ten minutes, another four attempts to enter
the correct code are possible.
01 2 3 Code lock setting
*** * EC700B
The code lock setting of the code lock function is shown when
pressing arrow right on the time/date screen (see previous page).
S86268A
30MIN
01 2 3
S86086
01 2 3 The code lock is unlocked for 30 minutes after the engine has been
shut off. After this period, the code has to be entered again.
*
01 2 3 0MIN
**
S86087
01 2 3
*** The code lock is locked as soon as the engine is shut off.
Changing the code lock setting
Change from one setting to another with arrow up or arrow down
01 2 3 and press the confirm button for more than one second.
*** *
S86194
Instrument panels
Screen 2
X1 flow change
1111 hour
X1 100 L
The displayed values of flow in the screen are the ones at rat-
S86246
ed rpm and with one pump.
Screen 2.1
Screen 2.1 With this screen you can change X1 flow using either the up or
100 L down arrow button.
120 L
X1 140 L Each step is 20 L. The selected flow is marked with a square.
S86247 To go to the fine adjustment, Press the right arrow button. The
screen will automatically change to screen 2.2
Any time you press the confirm button for more than 1 seconds,
the current settings are saved and the screen goes to screen 2.
Any time you press the confirm button for less than 1 seconds,
the screen goes to screen 2 without saving the settings.
Screen 2.2
Screen 2.2
110 L With this screen you can make fine adjustments to the flow.
X1100 L 120 L Each step is 5 L (example: 100, 105, 110, 115, 120)
S86248 You can see also the selected flow beside the hydraulic symbol
(110 L)
To go to the previous adjustment screen 2.1, push the right arrow
button.
Any time you press the confirm button for more than 1 seconds,
the current settings are saved and the screen goes to screen 2.
Any time you press the confirm button for less than 1 seconds,
the screen goes to screen 2 without saving the settings.
NOTE! The X1 flow value is stored in the V-ECU.

Instrument panels
Right instrument panel 35
Right instrument panel
S86503
1 Air conditioner / heater (optional equipment) 2 Ignition key
Air conditioner / heater (optional equip-

ment)
3 7 4 5 8 6
The heating and air conditioning system is ON and ready for oper-
ation when the electrical power is ON. This system operates when
the automatic button is pressed.
1 Power off button
Press this switch to stop operating this system.
2 Automatic / manual button

Automatic mode
– Lamp of automatic button is ON
S82056
9 9 1 2 – Button for automatic air temperature control in accordance with
1 Power off button
the preset temperature(16 °C ~ 32 °C).
2 Automatic / Manual button – This is changed to the manual mode when operating any button
3 Display window
except temperature control button (4) and when system prob-
lem happens.
4 Temperature control buttons
5 Diagnosis button
– This is changed to the failure mode if there is any problem in
the system.
6 Compressor ON / OFF button
7 Air flow selector button
Manual mode
8 Recirculation button
9 Fan speed selector button
– Lamp of automatic button is OFF.
– To control temperature in nine steps.
C4 C3 C2 C1 H0 H1 H2 H3 H4
Cooling mode → heating mode
These are controlled by temperature control buttons (4).
Instrument panels
36 Right instrument panel
3 Display window
Auto mode
The display shows the preset temperature(16 °C ~ 32 °C).
Manual mode
To display C4 → C3 → C2 → H0 → H1 → H2 → H3 → H4
Failure mode
When the diagnosis button (5) is pushed for more than 3 seconds
and if there are any problems in the system, an error code is dis-
played in display window (3).
When required, contact an authorized dealer workshop.
4 Temperature control buttons

When pressing or while pressing the buttons (up or down buttons),
the preset temperature is adjusted.
The temperature is shown in display window (3).
To certify the temperature by fahrenheit, press 2 buttons (2
temperature control buttons (4)) more than 5 seconds simul-
taneously.
To return to the centigrade, redo the above.
5 Diagnosis button
When pressing this button, error code of the air conditioning and
heating system is shown in display window (3).
6 Compressor ON/OFF button

The cooling system operates only when fan speed control button
(9) is ON.
7 Air flow selector button

Ventilation is available in four modes.
8 Recirculation button
To circulate the inside air or to draw in the outside air.
When the lamp is ON, the air inside the cab is circulated.
When the lamp is OFF, the outside air is drawn into the cab from
outside.
9 Fan speed selector button

When pressing the left or right end of the button to decrease or in-
crease the fan speed, the related lamp lights up and the fan speed
changes.
OFF → 1st step → 2nd step → 3rd step → 4th step
Instrument panels
Right instrument panel 37
Ignition key
This key has three positions:
1 2
3 1 Stop position
The engine stops immediately.
2 Running (preheating) position

When the ignition key is in this position:
– The electronics is started up
– The electronics is up and running
S86219A
– The preheating will be connected.
1 Stop position
2 Running (preheating) position
3 Starting position IMPORTANT! Do not repeat to turn on and off the ignition key
under engine cooled (below 20 °C in coolant temperature).
The preheating function still remains when you repeat to turn
on and off the ignition key when the engine is under 20 °C,
A which may damage and fire cable.
Preheat the machine fully (the pointer of cooling gauge on
the instrument panel is within the range of ‘A’) to repeat to
turn on and off the ignition key for service or other purpose.
S86196
3 Starting position
When the ignition key is in this position, the starter motor will be
engaged. See page 59.
Instrument panels
Upper instrument panel
1
2
3
4
5
6
7
8
9
10
11
12
13
S86504
1 Engine speed control switch 8 Audible warning and confirm switch for attachment
bracket (quickfit) (not applicable)
2 Working lights switch 9 Recirculation air sensor (optional equipment)
3 Power maximum mode selector switch 10 Upper wiper switch
4 Auto idle selector switch 11 Washer switch
5 Travel speed selector switch 12 Lower wiper switch (optional equipment)
6 Boost / hammer / shear selector switch 13 Cigarette lighter
7 Right attachment bracket (quickfit) switch (not appli-
cable)
1 Engine speed control switch

F G
I H
This switch is used to select the engine speed.
rpm
Turning this switch, the engine speed will change incrementally.
According to the selected engine speed, working mode will be set
automatically and setting mode is displayed on the Message
Center Display in front instrument panel.
S86213
Instrument panels
Upper instrument panel 39
Except North America
Switch Engine speed (±40 rpm) Power shift

Mode Remarks
step (no load/load) current (±10 mA)
For maximum productiv-
Power max P 9 1900 / 1800 over 200 ity during hard digging
and trenching
For slightly hard opera-
Heavy H 1800 / 1700 over 230
tions
G1 8 1700 / 1600 over
For economical opera-
General G2 7 1600 / 1500 over 270 tion during general appli-
cations
G3 6 1500 / 1400 over
F1 5 1400 / –
For Maximum lifting power
Fine F2 4 1300 / – 450
and moderate control
F3 3 1200 / –
I1 2 1000 / –
For warm-up and very pre-
Idle 610 cise operation
I2 1 800 / –
North America
Switch Engine speed (±40 rpm) Power shift

Mode Remarks
step (no load/load) current (±10 mA)
9 For maximum productivity
Heavy H 1900 / 1800 over 200 during hard digging and
trenching
G1 8 1800 / 1700 over 230
For economical operation
General G2 7 1700 / 1600 over during general
270 applications
G3 6 1600 / 1500 over
F1 5 1500 / –
For Maximum lifting power
Fine F2 4 1400 / – 450 and moderate control
F3 3 1300 / –
I1 2 1000 / –
For warm-up and very pre-
Idle 610 cise operation
I2 1 800 / –
Instrument panels
2 Working lights switch

1 0
2 Position 0 Lights OFF

Position 1 Instrument panel lamp and boom working lights ON.
Position 2 Instrument panel lamp, boom working lights and deck work-
S82287 ing lights ON.
3 Power maximum mode selector switch

(except NA)
0
Position 0 Power maximum mode DEACTIVATED
1
Position 1 Power maximum mode ACTIVATED
At 9 step of the engine speed control switch,
S82052A Position 0 H mode
Position 1 P mode
If the machine is not operated in the P mode for more than 5 sec-
onds and the auto idle selector switch is activated, the engine
speed automatically goes down to idle mode. when the machine is
operated again, it is returned to P mode again.
At the P mode, it become H mode if 9 step is selected after turning
the engine speed control switch to another step.
4 Auto idle selector switch

0
Position 0 Auto idling DEACTIVATED
1 Position 1 Auto idling ACTIVATED
S82288
The engine speed will be lowered automatically to idle mode to re-
duce fuel consumption if any of control levers, travel levers (ped-
als) or engine speed control switch are not operated for 5 seconds
or more. If any one of the above is operated, the engine speed re-
turns to the speed set with the engine speed control switch.
5 Travel speed select switch

0
Position 0 Travel at LOW speed only
1
Position 1 Travel at LOW or HIGH by automatic shift in accordance
with the travel condition,
S82289
IMPORTANT! Make sure to stop the machine before chang-

ing the travel mode.
Travel with low speed on a slope, soft ground or confined
place.
Use low speed fixed when loading the machine on a trailer.
Instrument panels
6 Boost / hammer / shear selector switch

NOTE! This instruction can be changed according to the
types of operating levers. For more information about operat-
ing lever, see page 55.
0 1
If X1 (hammer / shear) is not equipped,
2 Position 0 Boost mode
If button (C) on the right operating lever is pressed, digging
power is increased for 9 seconds.
S82290A
Position 1 Hammer mode
In this mode, boost does not function.
Position 2 Shear mode
In this mode, digging power is increased for 9 seconds
when the button (C) is pressed.
If X1 (hammer / shear) is equipped,

C
A If X1 (hammer / shear) pedal control is fitted
D E
NOTE! The pedal should be adjusted whether it is used for
hammer or shear, see page 57.
B Button (E) is for horn in all position (position 0, 1 & 2)
Button (D) is not assigned.
Position 0 Boost mode
If button (C) is pressed, digging power is increased for 9
seconds.
In this mode, X1 (hammer / shear) does not function.
S86214 Position 1 Hammer mode
If pedal forward (A) is pressed, the X1 will work.
If button (C) is pressed, the X1 will work.
If pedal forward (A) or backward (B) is pressed, the X1 will
work.
seconds.
If X1 (hammer / shear) 1-switch control is fitted

Button (E) is for horn in all position (position 0, 1 & 2)
Button (D) is not assigned.
If the button (C) is pressed, digging power is increased for
9 seconds.
If button (C) is pressed, the X1 will work.
seconds.
Instrument panels
If X1 (hammer / shear) 2-switch control is equipped

If button (E) is pressed, digging power is increased for 9
seconds.
If the button (C) is pressed, the X1 will work.
If the button (D) is pressed, the X1 will not work.
If button (C or D) is pressed, the X1 will work.
If button (E) is pressed, digging power is increased for 9
seconds.
7 Right attachment bracket (quickfit) switch (not

applicable)
8 Audible warning and confirm switch for attach-

ment bracket (quickfit) (not applicable)
9 Recirculation air sensor (optional equipment)

This sense the room temperature when the automatic air condi-
tioner is applied.
S82292
0 10 Upper wiper switch

1
Position 0 Upper wiper is switched OFF
2 Position 1 Upper wiper is switched ON intermittently
Position 2 Upper wiper is switched ON
S82291
IMPORTANT! Do not lift the front window while the wiper
motor is running.
11 Washer switch
0
Position 0 Washer is switched OFF
1 Position 1 Washer is switched ON
S82293
IMPORTANT! Never press the washer switch for more than
20 seconds.
Do not use if the washer fluid container is empty.
Instrument panels
0 12 Lower wiper switch (optional equipment)

Position 0 Lower wiper is switched OFF
1
Position 1 Lower wiper is switched ON
S80494A
13 Cigarette lighter
Press it down, and in a few seconds it will return to the original po-
sition. At this moment, it is ready to use.
S86221
Instrument panels
Left instrument panel
1
2
3
4
5
6
7
8
9
13
10
11
12
S86505
1 Mute switch (optional equipment) 8 Left attachment bracket (quickfit) switch (optional equip-
ment)
2 Extra work lamp switch (optional equipment) 9 Hour meter
3 Beacon switch (optional equipment) 10 One / two pump selector switch (optional equipment)
4 Room lamp switch 11 Automatic / manual selector switch
5 Seat heating switch (optional equipment) 12 Emergency engine stop switch
6 Overload warning switch (optional equipment) 13 Water separator heater switch (optional equipment)
7 Travel warning sound stop switch (optional equip-
ment)
0 1 Mute switch (optional equipment)

This switch is used to mute the sound of speaker for radio.
1
S82295
Position 0 OFF
Position 1 ON
0 2 Extra work lamp switch (optional equipment)

1
Position 0 Extra work lamps are switched OFF
Position 1 Extra work lamps are switched ON
S82296
Instrument panels
Left instrument panel 45
3 Beacon switch (optional equipment)

0 This switch is used to operate the lamp that show the status of
swing.
1
S82297 Position 0 Beacon is switched OFF

Position 1 Beacon is switched ON
0 4 Room lamp switch

1 Only when this switch is at "ON" position, the buttons (A, B, C)
connected to the cab light will work.
S82298
Position 0 Cab light is switched OFF
Position 1 Cab light is switched ON
Position 1 and pressing the button B, the cab light will be turned on.
C
Position 1 and pressing the button C, the cab light will be turned on.
Position 1 and button B or C is pressed: When pressing the button

2
A, the cab light will be turned off.

1
OFF
A B
S83368
0 5 Seat heating switch (optional equipment)

1 This is used to warm the operator seat.
Position 0 Seat heating OFF

S82306
Position 1 Seat heating ON
The seat heating functions when this switch is in position (1) and
the temperature is under 11 °C (52 °F). The seat heating stops
when the temperature is up to 28 °C ( 82 °F), and reworks when the
temperature turns down under 11 °C (52 °F) again by the first ther-
mostat. If the first thermostat malfunctions, the second thermostat
cuts off the seat heating at 29 °C (84 °F).
IMPORTANT! Position the seat heating switch OFF for fire
prevention when the seat heating is not needed (when leav-
ing the operator’s seat).
Instrument panels
6 Overload warning switch (optional equipment)
WARNING!
When the overload warning lamp is ON, stop the lifting
S80490A
operation and reduce the load. If not, it can cause a serious
accident, perhaps even a fatal accident.
When an overload happens, the warning lamp comes ON and the
buzzer sounds.
Position 0 Warning lamp & Buzzer are switched OFF

Position 1 Warning lamp & Buzzer are switched ON
1
1
S86260
7 Travel warning sound stop switch (optional

equipment)
This switch is used to mute the sound of speaker when traveling.
0
1
Position 0 Travel warning sound DEACTIVATED
S82257
Position 1 Travel warning sound ACTIVATED
8 Left attachment bracket (quickfit) switch (not

applicable)
Instrument panels
Left instrument panel 47
9 Hour meter indicator

The hour meter shows the total number of hours the engine has
operated. It records the hour only when the engine is running.
S86585
10 One / two pump select switch (optional equip-

ment)
This switch can be selected when the boost / hammer / shear
switch is set to hammer or shear.
Position 1 One pump, activated

Position 2 Two pump, activated
S86216A
11 Automatic / manual select switch

Position 1 Manual controlled
Position 2 Auto controlled
If the V-ECU malfunction, this switch must be switched to Manual

position.
After changing damaged part, set this switch to automatic posi-
tion(2).
2 To turn to auto mode from manual mode after changing or repair-
ing damaged part, the machine must be restarted.
1
S86217B
Instrument panels
12 Emergency engine stop switch

If the engine speed control switch does not work, set “Auto/Manual
select switch” to Manual position and use this emergency switch.
Position 0 Engine stop
If the switch is at this position for more than three seconds,
the engine will shut down.
This should be used when the engine may not stop, even
though the ignition key is turned to stop position)
Position 1 Idle speed.
0 Engages idle I2 mode (no load).
1 Position 2 High speed.
Engages H mode (no load) of engine speed.
2 Exception: G1 mode for North America.
S86218B
13 Water separator heater switch (optional equip-

0 ment)
1
The fuel can be heated up by the coil in the water separator. This
switch is used to operate the heater.
S86586
Position 0 Fuel heating OFF
Position 1 Fuel heating ON
Instrument panels
Rear instrument panel 49
Rear instrument panel
1 23 4
4 56
S82265G
1 Cab auxiliary heater (optional equipment) 3 Power socket

2 Service socket 4 Radio and cassette player
1 Cab auxiliary heater (optional equipment)

In cold weather, this auxiliary heater can be operated manually or
G H I J K L
at preset time to warm the cab and heat the engine. The battery
disconnect switch needs to be turned on before starting the heater.
Setting time and date
MO C
1 Press time setting button (A) until the time in display window (I)
1 begins to flash.
2 Adjust the current time by pressing backward button (E) and
forward button (F). When the current time (J) stops blinking in
S82265H a few seconds, the current time is set.
A B C D E F 3 When the current time (J) has stopped flashing, the date (H)
starts to flash. Adjust the date by pressing backward button (E)
A Time setting button
and forward button (F). When the current date stops blinking in
B Memory indicator a few seconds, the current date is set.
C Program button
D Heating ON / OFF button
E Backward button
F Forward button
G Symbol for remote control
H Program day of the week
I Display window
J Current time / program time
K Temperature display
L Heating indicator
Instrument panels
50 Rear instrument panel
Operating heater (direct)

1 Press heating ON / OFF button (D), and heating indicator (L)
and current time / program time (J) will be shown.
2 The initial setting time is for a duration of 120 minutes and this
time can be adjusted by pressing switches (E or F). Heating
time can be set up to 120 minutes.
3 Press heating ON / OFF switch (D) to OFF to change the heat-
ing time.
4 Press backward switch (E) until current time / program time (J)
flashes in display window (I).
5 Now adjust the operating time by pressing forward switch (F)
and backward switch (E) as current time / program time (J)
flashes. The heating time is set when it stops flashing.
Stopping heater
6 Press heating ON / Off switch (D), then heating indicator (L),
stops the heater; however the fan will continue to operate until
the unit is cool enough to safely shut down.
Preset heating time method
The preset heating time can be selected for 3 different times every
day or once a week.
1 Each preset time can be certified when program switch (C) is
pressed.
2 Press program switch (C) and memory indicator changes to 1.
3 Preset the time by pressing forward switch (F) or backward
switch (E), when current time / program time blinks.
4 Repeat the above steps and memory indicator (B) will change
to 2 and then to 3.
Heating ON / OFF switch (E) only blinks in the display window (I),
when memory indicator (B) is ON and at one of the preset operat-
ing times.
NOTE! When the battery disconnect switch is off, this preset
function is not operated.
2 Service socket
The service socket (VCADS Pro, SDU, MATRIS) is positioned to
the left, above the radio.
S83106 1 2 3
4 5 6
3 Power socket
This socket is for electrical appliances like mobile phone charger.
Capacity: under 12 V (4A)
1 2 3
4 5 6
S86548
Instrument panels
Rear instrument panel 51
4 Radio and cassette player
1 2 3 4 5
S86195A
6 7 8 9
1 Tune / Seek / scan
2 Band selection button
3 Tape eject button
4 Cassette tape loading slot
5 FF ( )/ REW ( ) button
6 Power / volume / balance / scan
7 Bass / treble
8 Preset (1 ~ 6)
9 Display
Instrument panels
52
Other controls
Levers and pedals 53
Other controls
Levers and pedals
1 3 3 2
6 4 4 5
S86222B
1 Left control lever
2 Right control lever
3 Travel levers
4 Travel pedals
5 Optional pedal (X1)

6 Optional pedal (Straight travel)
Other controls
54 Levers and pedals
1 Left control lever

This lever is for swing upper structure and moving dipper arm.
1
3 4
S82045
1 Dipper arm out

S80232
2 Dipper arm in
3 Left swing
N Neutral (superstructure and dipper arm in neutral position)
4 Right swing
1 Dipper arm out
2 Dipper arm out and swing superstructure right
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
2 Right control lever

This lever is for moving boom and bucket.
3
1 2
S86225
1 Bucket in
2 Bucket out S80233
3 Boom lower
4 Boom raise N Neutral (boom and bucket are maintained at rest position)
1 Lower boom
2 Lower boom and bucket out
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
Levers and pedals 55
Three button lever
1 A Left operating lever

5
3 B Right operating lever
4 1 Rotator button
6 2 Rotator button
2
3 Horn button
A B 4 Unassigned
5 Boost / hammer
S82255
6 Horn button
Thumb with three button lever

5
4 1 Rotator button
6 2 Rotator button
2
3 Horn button
A B 4 Thumb bucket
5 Thumb bucket / hammer button
S82255
6 Boost button
Float with three button lever

5
4 1 Rotator button
6 2 Rotator button
2
3 Horn button
A B 4 Unassigned
5 Boost / hammer button
S82255
6 Float ON / OFF button
Five button lever
A B A Left operating lever

B Right operating lever
1 1 Unassigned
2 2 Unassigned
S80511D
Other controls
56 Levers and pedals
3-4 Travel levers and pedals

IMPORTANT! Keep your feet off the travel pedals when work-
ing.
Consider the track direction before operating travel pedals or
levers.
Travel direction will be reversed when the sprocket is at the
S82044A
front.
A Do not change the travel direction rapidly. Especially, in case
A Sprocket of stationary direction change, stop the machine.
These are used to move and stop the machine.
2 N Neutral (machine stops)

N 1 Forward
1 Push the lever forward or press down front end of the pedal to ad-
vance the machine, when the sprocket is at the rear of the machine.
2 Reverse
Pull the lever rearward or press down rear end of the pedal to re-
verse the machine, when the sprocket is at the rear of the machine.
1
1 2
2
S80138C

See page 57.
6 Optional pedal (straight travel)

See page 57.
Other controls
Optional parts 57
Optional parts
Position 1 Operating hammer

Position 2 Operating Shear or Crusher
Position 3 Lock the pedal
IMPORTANT! When the machine is not operated with this

1 optional pedal, ensure that the pedal is locked position in
order to prevent undesired operations.
3
S82300D
2 Optional pedal (straight travel)
Position 1 Operating straight travel

Position 2 Lock the pedal
IMPORTANT! When the machine is not operated with this

optional pedal, ensure that the pedal is locked position in
order to prevent undesired operations.
S86506A
Other controls
58 Optional parts
3 Changing control pattern of the machine

(optional equipment)
S B
Position S ISO type
Position B Backhoe loader type
E
S B Pattern change valve is equipped only on certain machines.
C
WARNING!
Warning decal attached on the machine regarding pattern
change should be carefully read before changing the
pattern change valve. Certify pattern change decal and be
aware of pattern of attachment before operating machine.
The machine control pattern can easily be changed to the ISO sys-
tem or to the backhoe loader hydraulic system by changing the po-
sition of pattern change valve (if fitted).
Use the following procedure to change the position of the pattern
change valve (The standard position of machine is ISO pattern
type (S).
S83499 1 Pull the knob (C) down and move the lever (E) to S (ISO type)
position or to the B (Backhoe loader type) position by turning.
1 5 2 After you set the machine control pattern, release the knob.
The patterns on the left side of the illustration show the possible
4 9 2 S 8 9 6
configurations for the left control lever.
The patterns on the right side of the illustration show the possible
3 7 configurations for the right control lever.
5 1
4 9 2 B 8 9 6
7 S83308 3
S83311
S83309
S83310
Dipper arm out (1): Move the control le- Swing right (2): Move the control lever Dipper arm in (3): Move the control le-
ver to this position in order to move the to this position in order to swing the su- ver to this position in order to move the
dipper arm outwards. perstructure to the right. dipper arm inwards.
S83314
S83312 S83313
Swing left (4): Move the control lever to Boom lower (5): Move the control lever Bucket dump (6): Move the control le-
this position in order to swing the su- to this position in order to lower the ver to this position in order to dump the
perstructure to the left. boom. bucket.
S83315 S83316
Boom raise (7): Move the control lever Bucket close (8): Move the control le- HOLD (9): When the control lever is re-
to this position in order to raise the ver to this position in order to close the leased from any position, the control le-
boom. bucket. ver will return to the HOLD position.
Movement of the superstructure will
stop.
Other controls
Control lock-out system 59
Control lock-out system
WARNING!
Move the control lock-out lever down to lock the system
securely. Unless the control lock-out lever is on the
“Locked” position (B), operating levers can be operated by
careless touch, which could cause serious injury.
Unlocked position (A)

The control lock-out lever is in "Unlocked" position (A) for working
A and travelling operations.
2 3 4
When the control lock-out lever is in this position the engine
can not be started.
B 1 Locked position (B)

S80638F The control lock-out lever is used to lock out the attachment,
swing and travel unit.
1 Control lock-out lever
Place this lever on the left control console to “Locked” (B) posi-
2 Left control lever tion to lock out the hydraulic control levers and pedals.
3 Left control console
When the control lock-out lever is in this position the engine
4 Backrest can be started.
Other controls
60 Operator comfort
Operator comfort
Operator seat
The operator seat meets the requirements according to EN
ISO7096. This means that the seat is designed in order, in the best
possible way, to minimise the whole body vibrations which the op-
erator is exposed to while operating.
WARNING!
Do not adjust seat when an excavator is in operation.
IMPORTANT! Installation and maintenance should be carried
out by authorized and competent personnel only.
Mechanical suspension seat

6
1 Seat inclination adjustment
Push the lever (1) down to adjust.
4
2 Suspension adjustment
3 9
Use the wheel (2). Set the wheel according to the weight of the op-
10 1 erator.
2 3 Back rest inclination adjustment
Lift the lever (3) and press the back-rest rearward to required po-
sition.
4 Slide adjustment
Lift the lever (4) and push the seat forward or rearward.
5 Arm rest angle adjustment
7
Adjust the angle of the arm rest by turning the wheel.
6 Seat belt
8 7 Head rest restraint adjustment
8 Lumber support adjustment
5 9 Horizontal position adjustment
For longitudinal adjustment of the seat and consoles, lift the lever
(9) and push the seat and consoles forward or rearward.
10 Height position adjustment
For height adjustment of the consoles, use the wheel (10).
NOTE! Never adjust the height of the seat with the suspension
adjusting wheel.
S82084
IMPORTANT! The operator seat is adjusted in a correct way
in order to obtain the best possible comfort.
1 Seat inclination adjustment
2 Suspension adjustment
3 Backrest inclination adjustment
4 Slide adjustment
5 Armrest angle adjustment
6 Seat belt
7 Headrest restraint adjustment
8 Lumber support adjustment
9 Horizontal position adjustment
10 Height position adjustment
Other controls
Operator comfort 61
Air suspension seat (optional equipment)

The operator seat is also available with air suspension for even
better comfort. The adjusting possibilities are the same as for a
mechanical suspension seat except adjustment of air suspension.
To adjust air suspension of the seat,
1 Turn the ignition key "ON" or start engine.
2 Lift operator’s weight off the seat.
3 Press and hold the valve (2) until air bag is completely in-
flated.
4 Sit and pull on the valve (2) to deflate.
5 Stop deflating when seat starts lowering.
NOTE! After adjusting the suspension with operator’s weight,
the suspension height should be in the position within sus-
2
pension stroke.
S86594
Seat belt
WARNING!
Change the belt immediately if it is worn, damaged or if the
machine has been involved in an accident where the belt
had to take some strain.
• Modifications to the belt or its mountings are not permitted.
• The seat 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:
– Use a mild soap solution
– Allow the belt to dry while it is fully pulled out, before rolling it
up.
– Make sure the belt is fitted in a correct way.
Other controls
62 Operator comfort
Front window, opening

IMPORTANT! Move the control lock-out lever down to lock
B
the hydraulic system securely before opening or closing the
window.
A
1 Lower the attachment to the ground and stop the engine.
D
2 Pull both latches (E) while holding both grips (F), and then
move the window upward in order to unlatch the window from
the locked position (G).
C NOTE! Stop lifting as soon as the window is unlatched.

3 Hold both grips (F) only and pull the window upward and rear-
ward, and then fix it in the locked position.
S82107A
WARNING!
Do not hold latches (E) after unlatching the front window to
avoid possible injury to your hand.
G
Front window, closing
E
1 Lower the attachment to the ground and stop the engine.
F
2 Pull both latches (E) with holding both grips (F) to move the win-
dow out of the lock position.
S82110
3 Grip handle (F) only and pull the window downward slowly.
4 Fix the window securely and tighten in the locked position (G).
Lower window, removing

1 Open the front window.
2 Grip the upper part of lower window with both hands and pull it
upward.
3 Store the removed window inside the cab door.
S86227 Ensure that the lower window is locked in the storing posi-
tion.
To release the lock, turn the locking lever (A) and push the
button (B) simultaneously.
Be careful not to drop the window when releasing the lock.
B
A
S82085
Other controls
Operator comfort 63
S82087A
Door lock
It is used for keeping the cab door secure in the open position.
1 Push the door against outside of the cab.
2 Ensure it is securely fixed to the lock (A)
Press the lever (B) inside the cab to release the door.
S86264
Roof window and rain shield

A IMPORTANT! Do not clean the rain shield (B : optional equip-
ment) and roof window (A) with thinner, it will damage the
B polished surface.
S82185A
Sunlight protection roof

F
When installing the sunlight protection roof, consider other option-
al equipments, for example, rain shield, anti-vandal kit and so on.
NOTE! Do not step on the sunlight protection (F).
S82185B
Other controls
64 Operator comfort
2 Sun shade
1 3 Use the front, roof and rear sun shades to protect from the sun light
coming in through windows.
S83356
1 Front sun shade

2 Roof sun shade
3 Rear sun shade
Glove compartment
1 2
WARNING!
Do not keep tools or a weighty thing in the glove. They can
be dropped out of the glove by vibration of the machine or
their weights when the machine is operated, which may
cause accidents, perhaps even fatal accidents.
S8208
1 Glove
2 Latch
Coat hook
The coat hook (A) is inside the cab.
NOTE! Do not hook any item that may obstruct the view of the
operator.
A
S83357A Cup and drink holder
Use the cup and drink holder to hold a soft drink can in place.
S86255A
Other controls
Operator comfort 65
Ashtray
Pull the top edge of the ashtray in order to open it.
Pull the ashtray upward out of the console when cleaning it.
NOTE! Make sure that you close the ashtray after use in order
to prevent any possibility of fire.
S86263
Storage for the Operator’s manual

A storage compartment (A) is located at the rear side of operator
seat. Operator’s manual should be always kept in the storage
compartment.
A NOTE! Do not store tools in the storage compartment.

This could damage the compartment.
S83362
Window fixer
A Fix the windows with window-fixer to prevent them from shaking
from machine operation.
B
S83361
A Window fixer
B Windows
Fire extinguisher (optional equipment)

Mount fire extinguisher as follows,
Remove two bolts (1) installed in the right rear side in a cab and
install the fire extinguisher.
1
1
S81001
Other controls
66 Operator comfort
Emergency exit
The cab has two emergency exits, the door and the rear window.
Regardless of the rear window types, the fixed or sliding type,
break the glass with the hammer attached on the rear left side in a
cab.
IMPORTANT! The hammer (B) must not be removed or used
for other purposes than in an emergency situation. A miss-
ing hammer must be replaced immediately.
C
S82185 B
A
A Door
B Hammer
C Rear window
Protection from falling or scattering materi-

als (optional equipment)
C
Install the necessary protection guards according to working con-
ditions where falling or scattering materials are capable of entering
the operator’s cab.
Install front guards when working with a breaker.

In mining applications, FOPS shall be adopted.
B
The above recommendations are based on standard working, in-
stall the necessary additional protection guards in accordance with
job site conditions.
Prevent persons from entering or remaining in the dangerous ar-
ea.
S82142
Front window cleaning ;
1 Release the bolts (A or D), and then tilt the FOG or net.
A 2 Clean the front window
3 Fasten the bolts (A or D) with regulated torque by pushing
A Bolts the FOG or net.
B+C FOG
C FOPS
WARNING!
Do not operate the machine while FOG (Falling Object
Guard) is tilted. Otherwise, FOG can be damaged by the
E bucket.
D S82310
D Bolts
E Safety net
Other controls
Operator comfort 67
Anti-vandalism (optional equipment)
A B WARNING!
Be careful of installing anti-vandal covers, otherwise
people can slip up, which may do harm to people and cause
damage to the machine.
Anti-vandal covers are stored in two places, on the cab and by the
S82264 tool box.
Four covers stored by the tool box are installed at front windows
(A) and door windows (B)
Three covers stored on the cab are installed at right side window
(C) and rear window (D).
The wing nuts (E) are tightened not to be loosen when operating
C
the machine.
NOTE! When storing the covers, ensure that the locking

screws on the covers are not interfered between covers.
S82263
E
S82220 S82332
Air conditioner / heater (optional equip-

ment)
See page 35.
Radio and cassette player

See page 51.
Other controls
68
Operating instructions
Running-in instructions 69
This chapter contains rules which must be followed in order to op-
erate the machine safely. However, these rules are to be followed
in conjunction with laws or other 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.
70 Safety rules when operating
Safety rules when operating

Operator obligations
■ The operator should operate the machine in such a way that
the risk of accidents is minimised for both operator and persons
present at the work site.
■ The operator must be thoroughly familiar with how to operate
and maintain the machine and should undergo adequate train-
ing on the machine.
■ The operator must follow the Operator's Manual rules and rec-
ommendations, but also pay attention to any statutory and na-
tional regulations or specific requirements or risks which apply
WARNING! at the work site.
An operator of and the management ■ The operator must be thoroughly rested and must never oper-
for a construction machine are ate the machine when under the influence of alcohol, medicine
responsible for the working area of or other drugs.
the machine and must turn away any
person who is not authorised to be ■ The operator is responsible for any load while working with the
there when the machine is operating. machine.
The operator must keep a good look- – There must be no risk of the load falling off while operat-
out forwards and rearwards to avoid ing.
the risk of running into persons or – Refuse to take a load which is an obvious safety risk.
objects.
– Respect the stated maximum load for the machine. Pay
attention to the effect of different distances to the centre of
gravity and the influence of different attachments.
■ The operator must be in control of the working area of the ma-
chine.
– Prevent persons from walking or standing under raised
excavating equipment, unless it has been made safe or
supported.
– Prevent persons from entering or remaining in the danger
area, i.e. a distance of at least 7 m (23 ft) in all directions
from operating machines. The operator may allow a per-
son to remain in the danger area, but should then observe
caution and operate the machine only when the person is
visible or has given clear indications of where he or she is.
– Prevent persons from being in the cab of a vehicle which
is placed so that there is a risk that the cab may be hit by
other machines or falling objects, e.g. stones or logs. This
does not apply if the cab is sufficiently strong or protected
to withstand the impact of such external forces.
The operator may only take an instructor on board, if there is an
approved place for the same.
WARNING!
It is forbidden to sit or stand in an unsuitable place on the
machine, i.e. on the attachment (bucket, fork, platform, etc.)
or any other mounted attachment, so that the operator can-
not handle the machine in a safe way.
Safety rules when operating 71
Operator’s safety
■ The machine must be operational, i.e. faults which can cause
accidents must be rectified.
■ Suitable clothing for safe handling and a hard hat should be
worn.
■ A loose mobile telephone must not be used, as it may interfere
with important electronics. The mobile telephone must be con-
nected to the electrical system of the machine and have a fixed
external aerial fitted according to the instructions of the manu-
facturer.
■ Always sit in the operator seat when starting the engine/ma-
chine.
■ Keep your hands away from areas where there is a risk of
crushing, e.g. 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 ma-
chine. 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!
■ The door must be closed.
■ Check that the attachment is properly attached and locked.
■ The vibration (shaking) which arises when operating may be
harmful to the operator. Reduce this by:
– adjusting the seat and tightening the seal belt.
– picking the smoothest operating surface for the machine
(levelling the surface when necessary).
– adapting your speed.
■ The cab is designed to meet the requirements for falling ob-
jects, the weight of which agrees with testing methods accord-
ing to "FOPS".
■ In case of travelling on uneven ground, do not let the machine
lean more than 10° to one side.
■ The cab has two emergency exits, the door and the rear win-
dow.
■ Only walk and step on surfaces which are provided with anti-
slip protection.
72 Working within dangerous area
Working within dangerous area

High voltage overhead power line
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 con-
tact the power company responsible, before beginning any work
near high voltage power lines. Go through the special instructions
issued by the power company for work/presence near the power
lines.
Regard all power lines as if they were live even if they are sup-
posed to be without current. Working 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.
■ Remember that the voltage of the power line determines the
safety distance. Electrical flash-over may occur and damage
machine and operator at fairly great distances from the power
line.
■ Find out what action to take if a person has been exposed to an
S82201 electric shock.
IMPORTANT! Also when transporting the machine, take over-
head power lines into consideration.
IMPORTANT! There can be a visual distortion through roof
window. Real distance should be reconsidered.
Voltage Minimum distance to power line

0 ~ 1 KV 2 m (7 ft)
1 ~ 55 KV 4 m (13 ft)
55 ~ 500 KV 6 m (20 ft)
WARNING!
Make sure that the machine does not come into contact
with power lines while the power is switched on. Injuries
will arise if part of your body should come into contact with
a machine which is conducting electrical power.
Underground cables and pipes

Make sure that authorities or companies responsible for cables
and pipes have been contacted and that their instructions are fol-
lowed. Also check which rules apply to ground personnel regard-
ing exposing cables and pipes. Normally 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 113. The position of the pipe or cable may devi-
ate from the drawing or distances may be incorrectly determined.
Regard all electrical cables as live.
Working within dangerous area 73
Overhead railway power lines

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 person-
nel again.
WARNING!
Bear in mind that the power line over the adjacent track
may be live.
Operating under ground

■ Special equipment, e.g. certified engine is required within the
EU and in EES countries. Talk to your dealer.
Working in confined spaces

■ Check that there is sufficient room for machine and load.
■ Move slowly.
Operating (working) on public roads

■ Road signs, traffic restricting arrangements and other safety
devices, which may be required when considering traffic speed
and intensity or other local conditions, must be used.
■ when moving the machine with a suspended load, special at-
tention must be observed. when required, request the help of a
signal man.
■ Rotating 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.
■ Operating should be comply with the local or national laws and
regulations.
Working in low light conditions

■ When working in low light conditions, use head light.
■ In buildings, tunnels, etc., switch on the lights.
■ Do not operate the machine when visibility is poor such as a
heavy fog, snow or rain.
Working in other dangerous areas

■ Observe great care at marked danger areas.
■ Do not operate too close to the edge of a quay, ramp, etc.
74 Measures before operating
Measures before operating
WARNING!
Breaking these rules may lead to an accident or serious
injures.
– Read the Operator’s manual.
– Carry out daily service, see page 161. In cold weather, make
sure that the freezing point of the coolant is sufficiently low and
that the lubricating oil is intended for winter use.
S80644 – Clean / scrape ice off the windows.
– Check the level of hydraulic fluid, refill if required.
– Check that there is sufficient fuel in the fuel tank.
– Check that there are no faulty, 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.
– Check that there are no persons in the vicinity of the machine.
– Adjust the operator seat and fasten the seat belt.
– Check instruments, warning and control lamps, see page 75.
– Check the function of the attachment bracket (optional attach-
ment).
Measures before operating 75
Checking instruments, warning and control

lamps
3
2
4-10
11-17
18-24
25
26
S82304 S86015
Turn the ignition key to running position, then the following control lamps should light up:
The lamps are ON for three seconds and the buzzer sounds twice.
Battery charge warning and engine oil pressure warning lamps still light up before starting.
If any of these lamps does not light up, there must be a fault in lamps or in the electrical system.
All lamps should be OFF when the engine is running.
No Color Name No Color Name

1 Red Central warning lamp 14 Yellow Air cleaner clogging warning indicator
2 - Engine coolant temperature gauge 15 Yellow Air preheating indicator
Hydraulic oil temperature warning indi-
3 - Fuel level gauge 16 Red cator
Parking brake indicator Hydraulic oil filter clogging indicator
4 Red (not applicable)
17 Yellow
(not applicable)
Brake oil pressure warning indicator
18 Red Battery charge warning indicator
Low steering pressure indicator Attachment bracket (quickfit) indicator

Overload warning indicator (optional
7 Yellow Axle lock indicator (not applicable) 20 Red equipment)
8 Green Alignment indicator (not applicable) 21 Green Boost indicator
9 Blue High beam indicator (not applicable) 22 Green Float operation indicator (optional
equipment)
10 Green Left / Right turn signal indicator 23 Green Hammer operation indicator (optional
(not applicable) equipment)
Shear operation indicator (optional
11 Red Engine oil pressure warning indicator 24 Green
equipment)
Engine coolant temperature warning
12 Red indicator
25 - MCD (Message Center Display)
13 Red Coolant level indicator 26 - Scroll / Confirm buttons

76 Starting
Starting
NOTE! Make sure the control lock-out lever is in downward
(lock-out) position, otherwise the engine can not be started.
WARNING!
Check that no personnel or obstructions are around the
machine before starting the engine.
IMPORTANT! Do not hold the key at the starting position for
more than 20 seconds, which cause serious damage to the
starting system. If the engine does not start, turn the key
back to stop position and wait a couple of minutes before the
next starting attempt.
IMPORTANT! If abnormal sounds, excessive vibration, or
abnormal operation occur, turn the key to stop position
immediately to stop the engine.
IMPORTANT! Wait until the electronic system is completely
shut down before restarting.
At temperature above 0 °C (+32 °F)

1 Turn engine speed selection switch (A) to the low speed posi-
I
F G
H tion.
rpm
2 Sound the horn before starting the engine and keep an eye on
the people in the vicinity of the machine.
3 Turn the key to the starting position.
A
4 If the machine is equipped with a code lock, see page 33.
5 Release the key when the engine has started.
6 Warm up the machine.
S86231
At temperature below 0 °C (+32 °F)

1 Turn engine speed selection switch (A) to the low speed posi-
1 2 tion.
3
2 Turn the key to the running (preheating) position.
3 When the preheating indicator is off, sound the horn before
starting the engine and keep an eye on the people in the vicin-
ity of the machine.
4 Turn the key to the starting position.
5 If the machine is equipped with a code lock, see page 33.
6 Release the key when the engine has started.
7 Warm up the machine. Run at low speed and with a light load
S86219A until the oil in the engine and hydraulic system has warmed up.
1 Off position IMPORTANT! At temperature below -15°C (+5 °F), allow the
2 Running (preheating) position engine to idle for 10-15 minutes before operating.
3 Starting position Use recommended lubricating oil for winter use. See page
166.
During the cold season, fill the fuel tank after work has fin-
ished for the day to counteract the formation of condensation
water in the tank.
If necessary, start with booster batteries. See page 77.
Starting 77
Engine block heater (optional equipment)

This equipment is used to reduce the engine load which cause the
wear in the engine when starting the machine in cold weather re-
gion below -30°C (-22°F).
IMPORTANT! Specifications between the external power
source and block heater should be checked.
S83434
Starting with booster batteries
WARNING!
The batteries may explode, if a discharged or frozen battery
is connected directly to a fully charged battery, or if the
cables are connected wrongly.
When starting with booster batteries, check that the booster bat-
teries or other power source have the same voltage as the batter-
ies of the machine.
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 bat-
tery of the machine and the (+) terminal on the booster battery.
4 Connect the other jump lead between the (-) terminal of the
booster battery and a grounding point on the machine.
5 Connect the batteries of the machine by turning on the battery
disconnect switch.
6 Start the engine with the ignition key in a cab.
7 Leave the batteries connected for 5-10 minutes after starting
the engine.
8 Disconnect the jump lead from 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.
78 Stopping and parking
Stopping and parking

Stopping
1 Select as level ground as possible to park the machine.
2 Lower the attachment to the ground.
3 Leave the engine running at idling speed for approx. 30 sec-
onds before shutting off the engine. Otherwise the lubrication of
the turbocharger may be jeopardised, resulting in shorter serv-
ice life and great risk of bearing seizure.
4 Turn the ignition key to stop position.
5 Move the control lock-out lever down to lock the hydraulic sys-
tem securely.
6 If the machine is to be left for any length of time, the battery dis-
connect switch should be turned off.
Keep in mind that the theft and burglary risk can be minimised by:
– Removing the ignition key 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-
age is minimised.
– Removing all valuables from the cab such as cellular phone,
computer, radio and bags.
– Chaining the machine.
By etching in the PIN-number or the national licence plate number
of the machine on its windows, it is easier to identify stolen ma-
chines.
Parking
IMPORTANT! Select level ground to park the machine. If it is
unavoidable to park on a slope, put a wood block under each
track and thrust the bucket teeth into the ground.
120 1 Park the machine with proper condition that the piston rods of
the attachments will be protected against moisture, dust and
S82137 damage.
2 Follow the paragraphs 3 - 6 above of "Stopping".
3 Close and lock all windows, doors and all covers.
Stopping and parking 79
Long-term parking
Follow the instructions as for parking and in addition to that:
1 Wash the machine and touch up the paint finish to avoid rust-
ing.
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 cylin-
ders.
4 Fill the fuel tank and the hydraulic oil tank to the maximum
marks.
5 Make sure that the freezing point of the coolant is sufficiently
low (in cold weather).
6 Place the machine on level, firm ground where there is no risk
of freezing, landslide or flooding.
7 Cover the exhaust pipe (for parking out-of-doors).
Check after long-term parking

■ All oil and fluid levels
■ Tension of all bolts
■ Air cleaner
■ Hydraulic hoses
80 Transporting the machine
Transporting the machine

IMPORTANT! Loading, positioning, slinging and securing for
transporting the machine on a trailer or other vehicle should
be comply with the local or national laws and regulations.
IMPORTANT! The operator performing any work for transpor-
tation must be familiar with and be understood both operat-
ing information and related laws.
IMPORTANT! Please contact authorized personnel or Volvo
CE dealer for any information that you may require.
Disassembled parts for transportation
Below parts can be disassembled for transportation, which are re-
lated with transportation in weight and size.
5
1
4
} 8
7
3
} 9
}
2
10
6
S83437
1 Upper structure with lower frame 2 Under carriages

3 Boom cylinders 4 Counterweight
5 Boom with arm cylinder 6 Dipper arm with bucket cylinder
7 Bucket 8 Walkways and steps
9 Mirrors 10 Handrails
Total and disassembled specifications,

weight and dimension
Weight and dimension are very useful to estimate the method how
the disassembled parts are supposed to be transported. To comply
with the laws and regulations in certain region, use the specifica-
tions of total and disassembled parts. See the page 174 to page
178.
Track gauge, adjustment

The track can be retracted for transportation. See page 107.
Transporting the machine 81
Dipper arm with bucket cylinder, disassem-

bling
G H
A B C
E F
S83438
1 Position the machine on even, firm and level ground.

2 Retract the bucket cylinder and arm cylinder completely.
3 Lower the boom so that the dipper arm is on the ground. Insert
the block below the dipper arm.
4 Stop the engine.
5 Move the control lock-out lever down.
6 Disconnect the hose at point C and drain the oil.
WARNING!
The hot hydraulic oil can cause severe burns to
unprotected skin so cool the machine.
Residual hydraulic pressure can cause serious injury,
release internal pressure before any service is done on the
hydraulic system.
IMPORTANT! Take care of oil in an environmentally safe way.
7 Disconnect the hose at point B and plug the pipe with appropri-
ate tool at point B and C. remove the hoses (F).
8 Lift the dipper arm cylinder (G) slightly. Use cable sheath and
be careful that the cylinder is not damaged.
9 Remove the pin at point A.
10 Lower the dipper arm cylinder on the boom. insert the block be-
tween boom and cylinder.
11 Reinstall the pin at point A again.
12 Hitch the cable at point A, pin of dipper arm, with crane. Use ca-
ble sheath not to damage the pin.
13 Remove the pin at point E. Start the engine and move the boom
to disassemble from dipper arm.
14 Disassemble the dipper arm and move the machine rearward
to lower the boom on the ground.
15 Reinstall the pin at point E again.
16 Turn off the engine.
17 Lower the dipper arm on the ground. Insert the blocks below
the dipper arm.
18 Tie the cylinder rod for bucket and link not to be extended or
moved.
19 Rectify any damage to paint finish.
20 Apply the anti-rust agent and seal the machined faces.
Counterweight, disassembling
For the information about both counterweight for standard ma-
chine and one for optional equipment with removing device, see
the page 102.
Boom cylinder and boom with dipper arm

cylinder, disassembling
E 1 2 3
D
C F
G 4
5
B H
A 6
S83439
1 Stop the engine.

3 Lift the boom cylinder (left side of D) slightly. Use cable sheath
and be careful that the cylinder is not damaged.
4 Remove the locking pins (3) at point F and push the pin (1) to
the right side.
5 Start the engine.
6 Retract the boom cylinder completely and lower the boom cyl-
inder on the bedplate (G).
7 Turn off the engine and move down the control lock-out lever
down.
8 Reinstall the pin at point F again with shims and locking bolts.
Ensure that the locations of locking bolts (3) and shims (2) are
not changed into right side ones.
9 Same method is applied on the boom cylinder of right side.
10 Disconnect the hoses for boom cylinder and drain the oil.
WARNING!
hydraulic system.
11 Plug pipes and hoses with appropriate tool at disconnected
points, and then arrange the hoses not to be interfered with
other components.
12 Remove the locking plate at point H and push the pin (6) to the
right side.
13 Lift and lower the boom cylinder on the ground, insert the
blocks below the boom cylinder.
14 Reinstall the pin (6) and the locking plate again.
15 Disassemble the right boom cylinder with same procedure.
16 Disconnect the hoses at point A (hoses for arm cylinder and
bucket cylinder) and drain the oil
IMPORTANT! Take care of oil in an environmentally safe way
17 Disconnect the hoses at point B (hoses for hammer and shear)
and drain the oil.
18 If equipped with other attachments, disconnect hoses for them
and drain the oil.
other components.
20 Disconnect the wire harness on the boom.
21 Hitch the cable at point F with crane. use cable sheath not to
damage the pin.
22 Remove the locking plates (4) and pins (5).
23 Lift the boom with dipper arm cylinder and lower that on the
ground. Insert the block below the boom.
24 Tie the cylinder rod of dipper arm not to be extended or moved.
25 Reinstall the pins (5) and locking plates (4) again.
Under carriage, disassembling

B 5 2 3
B A
1
A 4
S83457
1 Stop the engine.

3 Remove the protecting cover (5) for hydraulic hoses.
4 Disconnect the hoses from 1 to 3 and drain the oil.
WARNING!
hydraulic system.

other components.
6 Remove the bolts at point 4.
7 Hitch the cable at points A and B with crane and lift upper struc-
ture with lower frame slightly.
8 Move the undercarriage aside with appropriate machine, for ex-
ample forklift.
WARNING!
Track can be fallen from forks. Do not approach to the track
until it is placed on the ground safely.
9 Lift the upper structure and lower that on the ground.
Mirrors, handrail, step and walkway, disas-

sembling
B C E
A 4 F
G
D 5 6
1 3 7 S83466
2
1 Stop the engine.
3 Loosen the bolts and nuts from 1 to 7.
WARNING!
Heavy objects can be fallen. Use a appropriate crane to lift
the disassembled parts.
4 Disassemble the mirrors (A), handrails (B, C and E), step (D),
walkways (F, 7ea) and brackets for walkways (G). For the in-
formation about weight, see page 178.
5 Be careful not to lose the disassembled parts.
A Dry-type precleaner, disassembling

1 1 Stop the engine.
2 B
D 3 Loosen the clamps (2) and remove the hose (B).
C 4 Put an appropriate cover at point (D) to protect from rain fall.
5 Loosen the bolts (1) and clamps (3).
WARNING!
The stop on the inside throat of the precleaner can be
sharp. Careless treatment can cause the injury.
S83422
6 Disassemble the precleaner assembly (A) and rubber adapter
3
(C).
7 Assemble the connector and put on a raincap on the top of air-
cleaner to protect from rain fall
8 Be careful not to lose the disassembled parts.
Rotating beacon lamp, disassembling

A When transporting the machine, disassemble the rotating beacon
lamp (A) not to be damaged.
B 1 Loosen the wing nut (B) and disassemble the rotating beacon
C lamp (A).
D 2 Keep the rotating beacon lamp (A) in the cab during transpor-
tation.
3 Put the rubber cover (C) on the bracket (D).
S83367
Assembling after transportation

Assembling the disassembled parts for transportation is followed
by the reverse order of disassembling process.
Some important things which should be taken into consideration
are described as below;
1 Missing items can be occur, be careful not to lose the disas-
sembled parts.
2 Keep feeding grease until the grease is squeezed out from
bushing. If greasing up is not enough, seizing on the pin will oc-
cur.
3 This machine has a hose rupture valve as an optional equip-
ment, but the one for boom cylinder is in the inward position.
This is opposite side of the other model’s. Improper installation
can cause the interference of pipes with track shoes at deep
digging position. Boom cylinder without hose rupture valve also
S83415 need a appropriate installation.
4 The bolts on the cover for main control valve has a special con-
figuration. Wrong assembly sometimes can occur. For detail in-
formation, contact Volvo CE dealer.
Loading and securing the machine
WARNING!
Do not lift the disassembled component with a person in
the cab or on other components.
WARNING!
Remove grease, oil, mud, ice etc. from the planks and
trailer bed to prevent the machine from slipping sideways.
IMPORTANT! Auto idle switch should be off to prevent any
possibility from increasing engine speed automatically when
15 B you operate the control levers and/or travel pedals with auto
idle switch ON.
S80040A IMPORTANT! Operate the engine at low speed and set travel
A A speed to low.
1 Place the trailer on a firm and level ground.
2 Apply the brake of the trailer.
3 Insert blocks (A) in front of and behind the tyres of trailer.
4 Fix loading ramps (B) securely.
– Make sure that the strength, width, length and thickness
of the planks are safe for loading.
2
3
– Make sure that the angle of loading ramp is 15º or less.
5 Check whether the right and the left loading ramps are of the
35
same height.
6 Block each track and secure the machine with tie downs of ad-
S83467
equate load rating so that the machine cannot move.Decide
the direction and travel slowly onto the loading ramps and trail-
er bed / platform.
– Load the machine so that the bucket cylinder rod does not
contact the trailer.
– Never operate any lever other than the travel levers (ped-
als) while the machine is on the loading ramp.
7 Stop the machine.
S83468 8 When some parts of machine are disassembled, load the dis-
assembled components on the trailers properly. If necessary,
put the blocks behind or below the components.
9 Remove the ignition key
10 Turn OFF the battery disconnect switch.
11 Lock the door and the access covers.
12 Cover the exhaust pipe to prevent turbocharger from damage.
13 Ensure that the machine or disassembled components are
firmly secured.
S86523A
S83469
Lifting the machine 87
Lifting the machine
WARNING!
Do not lift the machine with a person in the cab or on the
machine.
Use certified cables, slings, shackles and hooks with
adequate load rating.
Always lift the machine as shown below. Improper rigging
can allow the load to shift and cause injury or damage.
A B
mm inch m ft
475~525 19~21 11.4 37.5
S83498
NOTE! Lift the machine on flat, even and level ground.

1 Start the engine, and arrange the machine as illustrated.
2 Move the control lock-out lever down to lock the system
securely, see page 59.
3 Stop the engine, check the safety around the machine
4 Close and lock the front window cab door and engine hood se-
curely.
5 As shown in the decal for lifting, connect lifting cables or slings
with sufficient strength for the machine weight at the lifting
points correctly.
6 After installation of all hoisting equipment, lift the machine a lit-
tle to check its balance, if satisfactory, lift it slowly and evenly.
88 Towing the machine
Towing the machine
WARNING!
Use wire ropes which are sufficiently strong for towing.
In the event of slipping into swampy ground or towing heavy ob-

jects, attach a wire rope to tow the machine as shown in the illus-
S83019
tration.
Put wood blocks between the wire rope and the machine to protect
the machine and wire rope from damage.
NOTE! Do not use shackle holes (A) to tow the machine. The
holes are only for anchoring when transporting the machine.
S83470
A
Manual release of negative brake
If it is impossible to operate the machine due to the failure of the
pump, the negative brake should be released.
1 Apply hydraulic pressure of 40kg/cm2 at port (A) of the travel
motor.
2 Connect a hydraulic hose between the port (B) and (C) after re-
moving plugs.
C
B
S83435
A Brake released port

B Pressure gauge port
C Pressure gauge port
Operating techniques
89
This chapter contains advice and instructions on how to operate
the machine and examples of 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.
Accidents
■ Accidents and also incidents should be reported to the site
management immediately.
■ If possible leave the machine in position.
■ Only take necessary action so as to reduce the effect of dam-
age, especially personal injuries. Avoid action which may make
an investigation more difficult.
■ Wait for further instructions from the site management.
90 Rules for digging
Rules for digging
WARNING!
When digging, the operator must be seated in the operator
seat. No person may be on the outside of the superstruc-
ture, on the tracks or in the doorway, when the machine is
being operated.
First read the safety rules for operating, see page 70..
■ Always prepare work by carefully studying drawings and regu-
lations that apply to the site. Also study the ground conditions
and what the risk areas on the site look like. Turn off gas, elec-
tricity and water supplies, if this is necessary. Mark the position
of cables and pipes.
■ Fence off the area around the machine, if there is a risk that
people may get too close. Pay attention to a swinging machine.
■ 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 pri-
or to a landslip are indicated by small streams of loose material
just where the cracks are forming.
■ If the machine is provided with optional equipment, which is op-
erated with the pedals, the operator must assure him or her self
of that the anticipated movements are obtained when actuating
the pedals. An unexpected movement may entail risk of an ac-
cident.
■ A cab provided with protective grill over the roof window meets
the requirements for falling objects in accordance with stated
testing methods (FOPS/ISO 3449). Use a debris guard when
there is risk of heavy, falling objects.
IMPORTANT! With certain attachment combinations there is
a risk that the attachment may strike the cab. Avoid damage
by being careful when working close to the machine.
■ Never swing the bucket or load above people.
■ Never use the bucket for chopping.
■ If uncontrolled movements should occur, first release levers
and pedals, then shut off the engine immediately by turning the
ignition key to the stop position.
■ If red warning lamps light up and/or the buzzer is sounding, the
engine must be stopped immediately and the cause investigat-
ed.
■ The machine must not be equipped with a larger bucket/attach-
ment than permitted.
Rules for digging 91
■ When using equipment which generate knocks or vibrations,

e.g. hammer, the hydraulic cylinders must not be operated clos-
er than 10 cm (4 in) from their end-of -stroke positions.
■ In case of fire, the battery disconnect switch should be turned
off, if possible. Turn the battery disconnect switch key counter-
clockwise to switch off.
Loading on to a vehicle
S83414
Battery disconnect switch

WARNING!
Make sure that no persons are standing near the vehicle,
which is being loaded. Stones may fall off during the load-
ing.
■ If possible, position the machine higher than the vehicle to be

loaded.
■ Place the vehicle to be loaded so that the machine does not
have to swing and lift more than necessary.
■ Make sure that the driver of the vehicle to be loaded stays out-
side the working area of the machine and never swing the
bucket over the cab of the vehicle to be loaded.
■ Do not load the vehicle unevenly and avoid unnecessary spill-
age when loading. Do not make the load so high that earth and
stones fall over the platform sides.
■ Release the load carefully.
When working, do not:

■ use the slewing force for raking over the ground, demolition of
buildings or thrusting bucket teeth into the ground. It may cause
damage to the machine and attachments.
■ dig by using the travelling motors or thrusting bucket teeth into
the ground. This can overload the rear of the machine and
damage the track drive.
■ extend the hydraulic cylinder to its end of stroke. This can over-
load the end of the cylinder and shorten the life span of the ma-
chine. 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 national regulations may allow
it on some markets. If permitted, a properly installed rated
bucked hook and certified slings / shackles are required.
Contact a workshop authorised by Volvo CE.
■ operate by dropping the machine body.
92 Whole-body vibrations
Whole-body vibrations
Whole-body vibration emissions on construction machinery are af-
fected by a number of factors, such as the working mode, ground
conditions, speed, etc.
To a large extent the operator can influence the actual vibration

levels, because the operator controls the speed of the machine, its
working mode, the travel path, etc.
Therefore, the result can be a range of different vibration levels for

the same type of machine. For cab specifications, see page 171.
Guidelines for reducing vibration levels on earth-

moving machines
■ Use the proper type and size of machine, with optional equip-
ment and attachments for the application.
■ Keep the terrain 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 machine speed and travel path to minimize the vibra-
tion 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 recommen-
dations.
– Tire pressures.
– Brake and steering systems.
– Controls, hydraulic system and linkages.
■ Keep the seat maintained and adjusted.
– Adjust the seat and suspension for the weight and size of
the operator.
– Inspect and maintain the seat suspension and adjustment
mechanisms.
– Use the seat belt and adjust it correctly.
■ Steer, brake, accelerate, shift gears, and move the attachments
smoothly.
■ Minimize vibrations for long work cycle or long distance travel-
ling.
– Use suspension systems if available.
– If no suspension system is available, reduce speed to pre-
vent bouncing.
– Transport machines when there are long distances be-
tween worksites.
Whole-body vibrations 93
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 cab or access system.
– Minimize repeated handling and lifting of loads.
– Maintain reasonable weight and physical condition.
94 Working on slopes
Working on slopes
IMPORTANT! In order not to jeopardized the lubrication of
the engine, it must not be inclined more than 35 °. However,
note that the machine as such, depending on the load in
case, can perhaps not manage to work at this angle.
Caution on a slope
■ Be careful when opening or closing the doors on a slope, oper-
ational force may be changed rapidly. Make sure to keep the
doors closed.
■ Do not descend backward on a slope.
■ Do not change direction or travel a cross on a slope. Change
direction on level ground, if necessary first come down to level
ground and make a detour.
S80032B
■ If the machine slides, immediately lower the bucket to the

ground. The machine can turn over due to unbalance. Espe-
cially, do not swing with loaded bucket. In unavoidable case,
pile up earth on the slope, and then make the machine level
and stable.
S83374A
■ While travelling on a slope, keep the angle between boom and

arm at 90 - 110 °, raise the bucket 20 - 30 cm from the ground
90 ~110
20~30cm
S82159
In case of shoes slipping
If the shoes slip on a slope, thrust bucket into the ground, and pull
the arm in to assist the track drive to move the machine up the
slope.
In case of engine failure

In case of engine shut down while travelling on a slope, put the
travel lever to neutral position and lower bucket down to the
ground, then start the engine.
If the engine shuts down on a slope, do not operate the swing func-
tion, since the superstructure may be swung under its own weight
and cause tipping or side slipping.
Escaping from swampy ground 95
Escaping from swampy ground

Be very careful when working on swampy ground.
In case that one track gets bogged
If one track gets bogged down, raise this track using the bucket
and put a plank under the track.
IMPORTANT! When raising the machine using boom or arm,
use the bottom of the bucket. Do not use the bucket teeth.
Set the angle between boom and arm at 90 ° ~ 110 °.
After working in water or escaping from swampy ground, replenish
the grease to the attachment pins or the areas affected by the wa-
ter. Check the idler, rollers and track drive case oil, if contaminated,
S82162
change the oil.
In case both tracks get bogged

In case that both tracks get bogged down, put planks under each
track. Thrust the bucket into the ground, pull with the arm as when
digging, and move the travel lever forward to escape.
S82161B
Permissible depth of water

IMPORTANT! Be careful when the rear of the upper body is
under water, the engine fan may be damaged.
Permissible working depth in water is the center of upper rollers.
S82140
Do not fully submerge the upper rollers.
Upon leaving the water, make sure all the grease is replenished in
the areas affected by the water, e.g. bucket pin etc., remove the
old grease completely regardless of the maintenance period. Also
check the oil in the travel drive for contamination, and if necessary,
1 replace it.
S8214
1 Upper roller
2 Water level
Travelling on uneven ground

■ In case of travelling on uneven ground, operate the machine so
as not to lean to one side more than 10 º.
■ In case of travelling on flat ground, retract the attachment and
raise it 40 - 50 cm from the ground.
S82196
40~50cm
96 Working in cold weather
Working in cold weather

Read the advice for starting, see page 76.
The windows must be free from ice and snow before putting the
machine to work.
■ Watch out for ice on the machine causing slippery conditions.
Step only onto anti-slip surfaces.
■ Use an ice scraper on a long handle or a ladder when removing
ice from the windows.
WARNING!
Avoid contact between unprotected skin and very cold
metal objects, as the skin may freeze to the metal.
WARNING!
In very low temperatures the hydraulic system of the
machine will response slowly. Therefore, take care before
the system has reached operating temperature, so that
accidents are avoided.
WARNING!
Disconnect the electrical engine heater before servicing the
machine. There may be risk of burns and electrical shock.
Working with bucket 97
Working with bucket

IMPORTANT! Select the proper attachment to suit the
machine on which it will be installed. The type of attachment
varies with the machine type. Contact a workshop authorised
by Volvo CE.
The machine is prepared for several different type of optional
equipment to perform many types of work. Only the simplest oper-
ations are described below.
Backhoe work
90
Backhoe work is digging the material at a lower level than the ma-
chine is located.
90
When the angle between bucket cylinder and links, dipper arm cyl-
S82148
inder and dipper arm is set to 90° respectively, the working efficien-
cy of each cylinder will be at its maximum. Take advantage of this
angle to improve the work efficiency. The range for effective dig-
ging is when the dipper arm is between 30° forward and 45° rear-
ward. 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.
S82149
30 45
Ditching work
Install a proper bucket for ditching. Place the machine where the
ditching is performed effectively.
In case of a wide ditch, dig both sides in first, and then dig the cen-
ter area.
S82150
Loading work
Position the hauler or truck so as to achieve a small slewing move-
ment 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 effi-
ciency.
S82152
98 Working with bucket
Bucket, changing
Bucket, removal
A B
WARNING!
While striking the bucket pin with a hammer, metal chips
may fly into your eyes.
Always wear goggles, safety helmet and gloves while
working.
2mm
1 Lower the bucket lightly on the ground.
S80250A
2 Remove the lock bolt (A) and nut (B) of each pins.
3 Remove pins (C and D), then remove the bucket.
IMPORTANT! Block the removed bucket to stabilize it. Keep
the pins clean and do not damage O-ring (E).
E
Bucket, Installation
C
WARNING!
Do not insert your fingers into the pin bores to check
alignment, a serious accident could occur.
D
S80249E 1 Align the dipper arm to the bucket holes and link holes.
2 Apply grease to the holes.
3 Put O-rings (E) at the holes for the dipper arm.
4 Insert pins (C and D).
5 Install lock bolt (A) and nut (B) of each pins.
IMPORTANT! Leave a clearance of minimum 2 mm between
pin and nut, and grease the pins.
Working with long range attachment 99
Working with long range attach-

ment
WARNING!
Due to the length of the attachment, there is a risk that the
attachment may strike the cab. It needs to be used with
care in order to avoid damage to the machine/attachment or
personal injury.
IMPORTANT! Do not use any attachment not authorized by

Volvo CE.
Long range attachments can be used in clearing and dredging
lump of clay accumulated in the river and reminders of waste water
effectively.
■ Do not use long-range attachment in general excavating, be-
cause it is designed for excavating small amounts.
■ Operate the machine smoothly in order to keep stability and
safety when travelling.
■ Do not stop the machine abruptly, which may cause heavy jog-
gling of the attachment. It also causes excessive force to the at-
tachments which finally may damage the machine.
■ Never use power boost switch of attachments.
■ Boom, dipper arm and bucket have big inertial power compared
to standard equipments. Therefore, do not operate the machine
at the ends of stroke of each cylinder.
■ Do not travel the machine or raise the main body with the buck-
et grounded. It may give excessive force to pin around the
bucket.
100 Hose rupture valves (optional equipment)
Hose rupture valves (optional

equipment)
IMPORTANT! The hose rupture valve is pressure-loaded. So
do not dismantle the hose rupture valve yourself. Contact an
authorized Volvo CE dealer workshop when problems occur
on these valves.
WARNING!
The components inside the valve and under spring tension
may be expelled with great force and may cause personal
injuries. Never stand beneath a raised boom.
Attachment lowering after hose rupture
1 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.
2 When engine is stopped

The servo hydraulic pressure is maintained by a pressure in accu-
mulator 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 lower the boom, the pilot pressure will reduce at a
speed depending on your machine’s condition and equipment.
Collect the oil from the ruptured hose in a suitable vessel.
3 When engine is stopped and with no servo

hydraulic pressure
S83415
WARNING!
Hydraulic oil is hot, poisonous and under high pressure.
Oil which jets out can penetrate your skin and cause severe
injury. People who are injured by a jet of hydraulic oil need
medical attention at once.
B A
1 Loosen lock nut (B) and turn adjusting screw (A) counter-clock-
wise slowly.
Before turning the adjusting screw, mark its position to fa-
cilitate assembling later (setting pressure : 365 kgf / cm2)
The boom will then slowly be lowered to the ground.
2 Turn adjusting screw (A) to its original position.
S82184D 3 Hold adjusting screw (A) securely and tighten lock nut (B).
4 Contact an authorized Volvo CE dealer workshop.
WARNING!
Do not loosen the adjusting screw completely, the oil under
pressure may cause personal injury, and an uncontrolled
boom drop
Boom float position (optional equipment) 101
Boom float position (optional

equipment)
Float position means that both the boom cylinders’ piston and pis-
ton rod sides are connected to the hydraulic tank. The boom then
floats with the weight of the attachments when operating the boom
lever forward. The boom lifting is not affected by float position.
Float position gives better fuel economy, faster excavation cycle,
less wear and less vibration. When the float position is engaged,
the hydraulic oil of the machine can be used for other purposes
than lowering the boom, such as the dipper arm and bucket. These
functions then become faster and more efficient.
Keep the following in mind.
– Always make sure that the boom operating lever is in the neu-
tral position before activating the float position.
– Do not select the float position mode while the track or tracks
are elevated. Selecting the float position mode and operating
the boom operating lever forward (boom down position) while
the track or tracks are elevated could cause the machine to
drop down suddenly.
S83369 – Do not release float position mode while the boom operating le-
ver forward (boom down position) and bucket or tool is on the
ground. This could cause the machine to tilt up suddenly.
– Do not attempt to lift the track or tracks while the machine is in
float position mode.
Use the float position when the attachment has to follow the irreg-
ular ground, such as for bedrock clearance, grapple handling and
when unloading barges and flatbeds. Float position also makes
unloading more manageable.
1 Select the float position using button 1 on the right control lever
in order to activate the float function. The control lever should
1 have the float function, see page 55. The float operation indi-
2 cator on the front instrument panel lights up.
2 Float position is only in operation when you push the boom op-
erating lever forward. When the attachment is to follow the
S86564 ground, the boom operating lever must therefore be held for-
1 Float On / Off button wards all the time. The boom can then move upward and down-
2 Float with three button lever ward freely depending on the state of the ground.
3 Deactivate the float position by pressing the button 1 again.
The light on the instrument panel will go out.
S83062
Indicator on the instrument panel

102 Counterweight
Counterweight
WARNING!
Personal injury can occur from a counterweight falling
during removal and installation. Do not allow personnel
under or around the counterweight during removal and
installation.
Use certified cables and shackles of adequate load rating.
Improper lifting can allow the load to shift and cause injury.
Counterweight, removal (for standard

machine
IMPORTANT! Move the control lock-out lever down to lock
the system securely, see page 59. Attach a warning tag (do
not start the engine) to the left operating lever.
1 Position the machine on flat, firm and level ground, free from
D
any obstructions or interference.
2 Remove two covers and a plug on the top of counterweight.
3 As shown in the illustration, connect the lifting cables or slings
with sufficient strength for the counterweight at the lifting points
(A) correctly. In the point D, use eye bolt.
A
4 Disassemble six bolts (B, C).
C
5 Lift the counterweight fully to remove it.
B
6 Place the counterweight on suitable supports.
Counterweight, installation (for standard

machine)
S83440
2 As shown in the illustration, connect the lifting cables or slings
with sufficient strength for the counterweight at the lifting points
(A) correctly.
3 Lift the counterweight enough to fasten with bolts on the brack-
ets.
WARNING!
Do not insert your fingers between machine and
counterweight, a serious accident could occur.
4 Assemble six bolts (B, C).
5 Disconnect the lifting cables or slings from the counterweight
at the lifting points (A).
6 Install a plug and two covers on top of counterweight.
Tightening torque or specification of bolts :
B : bolts: 90.2±9 kgf m / 884.6±88 N m / 651.2±65 lbf ft
C : bolts: 280±5 kgf m / 2746±49 N m / 2022±36 lbf ft
D : eye bolt specification : M48-P5
Counterweight 103
Counterweight, removal (with optional

removing device)
Control levers and switch for operating the counterweight are lo-
cated on the pump room.
2 Position the boom and arm with the bucket on the ground.
3 Stop the engine and move the control lock-out lever down to
S83441
lock the hydraulic system securely, see page 59.
4 Inspect the counterweight removal device for defects, cracks,
or any other damage to the device and its operating system
components.
B
C
S83442
A Control lever
B Shut-off valve
C Solenoid valve control switch
5 Make sure that the counterweight (D) is firmly connected to lift-

D ing yokes (E) of the removal device.
Inspect all hoses and fittings for hydraulic system of the remov-
al device. Correct if necessary.
S86577
D Counterweight
E Lifting yoke
0
6 Be sure that the lever on removal control valve is in the neutral
2 1 position.
Position 0 : Neutral
Position 1 : Downward counterweight movement
Position 2 : Upward counterweight movement
S83443
104 Counterweight
7 Remove counterweight securing bolts.
S84016A
8 Start engine and keep the engine rpm at the low idle speed.
9 Open the shut-off valve.

0
Position 0 : Close valve
1
Position 1 : Open valve
S84019C
10 Turn on the solenoid valve control switch.
1
0
Position 0 : Turn OFF
Position 1 : Turn ON
S83434
0 11 Operate the directional control lever to downward position 1

2 1 slowly and smoothly to lower the counterweight on the ground.
Position 0 : Neutral
Position 1 : Downward counterweight movement
Position 2 : Upward counterweight movement
IMPORTANT! Be sure all personnel and equipment are clear

of the area where counterweight is being placed. Have an
assistant observation and be sure that the area of operation
S83443 remains clear during removal.
Counterweight 105
12 The counterweight can be placed directly on the ground, as-

suming the ground is flat and level. If not, set the counter-
weight on adequately sized and structurally sound blocks to
level it.
S84011
13 Lower the removal device to a position where lifting yokes (A)

are loose on the counterweight.
14 Remove clips (B) and pins (C) from lifting and yokes (A) con-
necting to counterweight.
15 Disconnect both yokes from the counterweight.
A 16 Operate the directional control lever to upward position, to raise
the removal device.
B 17 Turn the solenoid valve control switch to off position.
C 18 Turn the shut-off valve lever to close position.
S84007A
Counterweight, installation (with optional

removing device)
1 Position the machine on flat and firm level ground, free from
any obstructions or interferences.
2 Position the boom and dipper arm with the bucket on the
ground.
3 Stop the engine and inspect all pins on the removal device for
tightness. Do not operate the device with loose pins. Check all
A hoses and fittings in removal system. Tighten if necessary.
4 Make sure that the removal control lever is in neutral position.
B
5 Start the engine and keep at low idle speed.
C 6 Open the shut off valve and turn on the solenoid valve control
S84007A
switch.
7 Operate the control lever slowly to lower the removal device.
H While lowering the device, be sure to line-up the lifting yokes
A
with the lifting slots on the counterweight.
8 Connect the lifting yokes to the counterweight. Install pins (C)
and clips (B). Adjust the height (H) using nuts (A), if necessary.
9 Apply grease to the designated locations.
NOTE! The dimension (H), approximately 80mm (3.15in), was

adjusted properly during assembly at the factory.
S84007B
106 Counterweight
10 Move the directional control lever very slowly to the UPWARD

position, to raise the counterweight. While raising the counter-
weight, make sure that the upper frame and counterweight do
not interfere with each other.
11 Raise the counterweight to the bracket of the removal device
and ensure that the counterweight bolt holes line-up with the
holes in the rear of the upper frame and the nuts on the remov-
al device.
H NOTE! When the counterweight is on the upper frame and if
there is excessive clearance at (B) between the counterweight
and upper frame, lower the counterweight to the ground. Ad-
just the yokes to increase dimension (H). Reinstall counter-
weight.
NOTE! If there is no clearance at (B) and the counterweight
can not seat on the upper frame, lower the counterweight to
the ground. Adjust the yokes to decrease dimension (H). Re-
install counterweight.
S84015A B NOTE! Draw the counterweight into position by tightening the
mounting bolts to the specified torque.
12 When the counterweight is properly installed on upper frame,

operate control valve lever to the LOWER position slowly until
contact is made between the counterweight and upper frame.
Tighten the bolts in this order, C>D>E>F.
C D Tightening torque :
S84016 C, D Bolts : 280 ± 5 kgf m / 2746±49 N m / 2022 ± 36 lbf ft
E, F Bolts : 280 ± 5 kgf m / 2746±49 N m / 2022 ± 36 lbf ft
E F
13 Turn off solenoid valve control switch and close shut off valve.
WARNING!
To avoid injury, from unexpected counterweight movement,
do not enter directly under the counterweight during
removal or installation.
Verify and confirm that solenoid valve control switch has
been turned off after removal or installation of the
counterweight.
Adjustable track gauge 107
Adjustable track gauge

Track gauge, retracting
IMPORTANT! Do not retract the track gauge except trans-
porting purpose. Remove soil deposits and debris attached
S83484
to the central frame.
1 Position the machine on even, firm and level ground.
A 2 Stop the engine.
B 3 Remove bolts (A) of the track frame using a special tool (multi-
plier).
A
NOTE! Do not remove guide bolts (B)
4 Start the engine and swing the upper structure at a right angle
to the track to be retracted.
5 Apply downward pressure and raise the track frame slowly to
about 500mm above ground level.
If the track is not readily retracted, rotate the raised track slow-
ly to shake it gently into place.
C C NOTE! Do not adjust the track gauge if the angle between

boom and arm is below 90°
6 Lower the track frame to the ground.
7 Align the bolt holes and fasten bolts (C).
NOTE! Insert the corks into bolt holes to protect the holes
from debris and mud.
8 Adjust the opposite frame in the same way as above.
Both side retracting should be done
90 ~110
Track gauge, extending

500 mm
IMPORTANT! Remove soil deposits and debris attached to
S83485A
the central frame.
D 1 Position the machine on even, firm and level ground.
D Track to be retracted 2 Stop the engine.
3 Remove bolts (C) of the track frame.
NOTE! Do not remove guide bolts (B)
4 Start the engine and swing the upper structure at a right angle
to the opposite track extended.
5 Apply downward pressure and raise the track frame slowly to
about 60 mm above ground level.
IMPORTANT! Do not raise the track frame more than 60mm
not to damage the guide.
60 mm 6 Pull the machine with the arm and the track will be extended by
moving the central frame.
S83486A
E 7 Lower the track frame to the ground.
E Track to be extended 8 Align the bolt holes and fasten (A) using multiplier.
9 Adjust the opposite frame in the same way as above.
10 Adjust track tension.
NOTE! When tightening the bolts, use the dedicated tool as an
optional equipment.
Tightening torque: 275±30 kgf m / 2697±294 N m
/ 1986±217 lbf ft
108 Selecting track shoes
Selecting track shoes
Grouser Use Precautions when using

A Rocky ground, Travel in low speed when traveling on rough ground with obstacles
normal soil such as large boulders and fallen trees.
650 mm
Soft ground Travel in high speed only on flat ground. When it is impossible to
avoid travelling over obstacles, lower the travel speed to approxi-
mately half of low speed.
B
750 mm WARNING!
Cannot be used on rough ground where there are large
obstacles such as boulders or fallen trees.
Extremely soft Use only for ground where “A” and “B” are impossible to use. Travel
ground in high speed only on flat ground. When it is impossible to avoid
(swampy ground) travelling over obstacles, lower the travel speed to approximately
C half of low speed.
900 mm
WARNING!
Cannot be used on rough ground where there are large
obstacles such as boulders or fallen trees.
Lifting objects 109
Lifting objects
If the machine is used to lift objects within an area that is governed
by the European Machinery Directive 98/37/EC and its amend-
ments, the machine must be equipped with following safety work-
ing devices.
• A load hooking device.
• Hose rupture valve on the boom or in some countries hose rup-
ture valve on both boom and arm is required depending on risk
assessment.
• A overloading warning device.
IMPORTANT! It is the owner’s or operator’s responsibility to
be familiar with and comply with all national, state, municipal
regulations governing this type of work.
Contact your Volvo Construction Equipment dealer for more
information.
Keep the following in mind to ensure the highest level of controlla-
bility and safety when lifting.
– Operate on solid, flat, level ground.
– If ground conditions are unstable, e.g. loose gravel, sand or wa-
A ter, do not work with loads close to the rated load maximums
given on the machine load chart.
– Do not swing the excavator abruptly with a suspended load, the
effects of centrifugal force will impair machine stability.
– Do not use the swing or arm-in operation to drag a load.
– Do not operate the machine while someone is hanging on or in
the bucket or attachments
1 Load hooking device

The lifting hook whether mounted on a bucket or other attachment
must not be subjected to lateral loads. The load must be applied
longitudinally to the hook.
Always ensure that the load lies within the permissible lifting area
of the hook base when manoeuvring the arm and bucket.
B
Exceeding these limits can cause serious injury. Remember that

the operator is responsible in case of an accident.
NOTE! This represents the capacity of the hook and not the
rated load capacity of the machine which varies according to
ground conditions, reach, track position etc.
IMPORTANT! The use of load hooking device not recom-
mended by Volvo could result in structural damage to the
machine. Consult your Volvo Construction Equipment dealer
for detailed information when mounting a safety hook to a
S83203B
local sourced bucket.
A Permissible lifting angle 2 Hose rupture valve (optional equipment)

B Prohibited lifting angle See page 100.
3 Overloading warning device (optional equip-

ment)
See page 27.
110 Hydraulic hammer (optional equipment)
Hydraulic hammer (optional

equipment)
Main works
– Breaking stone
– Demolition work
– Road repairing
It is widely used for demolition of buildings, breaking road surfac-
es, tunneling work, smashing slag, and breaking or cutting stone.
S80354
Press the chisel firmly onto the surface at a right angle as shown.
90
90
S80355
When striking, press the chisel firmly onto the surface, and lift the
frame about 5 cm. Never raise the machine unnecessarily high.
S82171
If the surface is struck repeatedly but it does not break within 1

minute, move the chisel nearer one end and strike again.
Hydraulic hammer (optional equipment) 111
The striking direction of chisel and the direction of breaker body

are deviate slightly. Therefore, adjust the bucket cylinder so that
the direction of body and chisel is always the same.
S82172
Press the chisel firmly against the surface so idle striking is avoid-
ed.
S80359
Caution during hammer operation

Do not operate the cylinder to its end of stroke, leave about 5 cm.
S80360A
Do not slew the hammer against the rocks, concrete etc.
S82173A
112 Hydraulic hammer (optional equipment)
Do not move the chisel while it is striking a blow.
S82174
Do not strike horizontally, or in an upward direction.
S82175A
Do not bend with the chisel to make a hole in the ground.
S82176
Do not hoe the chisel.
S82177A
Do not raise the machine by extending the bucket cylinder to max-

imum.
S82178A
Signalling diagram 113
Signalling diagram
Manual signalling to operator of a mobile excavator as per SAE J1307.
The primary use of hand signals is for a signalman to direct the lifting, handling, and placement of loads attached
to working equipment. Hand signal usage may also be applicable to earthmoving operations and/or machine trav-
el when the operator´s visibility is obstructed.
If a rapid lifting, lowering or moving movement is required, the dipper arm movements should be carried out more
lively. If two different machines are used for lifting the same load, there should be an agreement beforehand how
the lift should be carried out and what signals should be given to the respective operators.
S81461 S81462
S81463
RAISE LOAD VERTICALLY LOWER LOAD VERTICALLY MOVE LOAD IN HORIZONTALLY

With either forearm vertical, forefinger With either arm extended downward, With either arm extended, hand raised
pointing up, move hand in small hori- forefinger pointing down, move hand in and open toward direction of move-
zontal circles. small horizontal circles. ment, move hand in direction of
required movement.
S81465 S81466
S81464
MOVE LOAD OUT HORIZONTALLY RAISE BOOM LOWER BOOM

With either arm extended, hand raised With either arm extended horizontally, With either arm extended horizontally,
and open toward direction of move- fingers closed, point thumb upward. fingers closed, point thumb downward.
ment, move hand in direction of
required movement.
S81467 S81469
S81468
SWING DIPPER ARM INWARD

With either arm extended horizontally, point with forefinger to direction of swing With both hands clenched, point
rotation. thumbs inward.
114 Signalling diagram
S81470
S81471 S81472
DIPPER ARM OUTWARD CLOSE BUCKET OPEN BUCKET

With both hands clenched, point Hold one hand closed and stationary. Hold one hand open and stationary.
thumbs outward. Rotate other hand in small vertical cir- Rotate other hand in small vertical cir-
cle with forefinger pointing horizontally cle with forefinger pointing horizontally
at closed hand. at open hand.
S81473 S81479
S81474
TURN THIS FAR TO GO

Raise forearm with closed fist indicating inside of turn. Move other fist in vertical With hands raised and open inward,
circle indicating direction of track or wheel rotation. move hands laterally, indicating dis-
tance to go.
S81480
S81475 S81476
COUNTER ROTATE MOVE SLOWLY

Place hand on head indicating side or reverse track or wheel rotation. Move other Place one hand motionless in front of
hand in vertical circle indicating forward rotation of other track or wheel. hand giving motion signal. Raise load
slowly is shown.
S81477 S81478 S81481
TRAVEL STOP
Raise forearm with closed fist indicating inside of turn. Move other fist in vertical With either arm extended laterally,
circle indicating direction of track or wheel rotation. hand open downward, move arm back
and forth.
Signalling diagram 115
S81482 S81483
EMERGENCY STOP STOP ENGINE

With both arms extended laterally, Draw thumb or forefinger across throat.
hands open downward, wave arms
back and forth.
Service position 117

This section deals with the safety rules which should be followed
when checking and servicing the machine. It also describes the
risks when working with unhealthy material and ways to avoid per-
sonal injuries.
Further safety rules and warnings texts are given within the re-
spective sections.
Service position
Before you begin any service work, park the machine for service
position as any of positions shown below.
WARNING! 1 Position the machine on even, firm and level ground.
2 Put the attachment on the ground.
If work has to be carried out on the
machine before it has cooled down, 3 Turn off the engine and remove the ignition key.
be careful with hot liquids and hot 4 Move the control lock-out lever down to lock the system
parts of the machine to avoid burns. securely, see page 59.
5 Pressurized lines and vessels should have the pressure re-
leased gradually to avoid risks.
6 Allow the machine to cool.
A suitable position is stated in the description for the different serv-
ice operations. If no particular position is stated, the machine
should be parked in service position A.
Service position A
Extend the bucket and dipper arm cylinder completely, and then
lower the boom on the ground.
4 3 5 6
S83406
Service position B
Extend the bucket cylinder completely, retract the arm cylinder
completely and lower the boom on the ground.
S83436
118 Entering / leaving / climbing the machine
Entering / leaving / climbing the

machine
S82193
WARNING!
Always observe this caution for safety.
■ Do not jump on/off a machine, especially never get on / off
when the machine moves.
■ Never grasp the control lever to get on / off.
■ Use handholds and steps when entering, leaving or climbing
the machine.
A
■ Use the three-point grip, i.e. 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.
■ Do not use hand rail (A) of the cab door as a support when en-
tering, leaving and climbing the machine. it is not strong
enough to be used as a support. it should only be used for clos-
ing the door.
S82103
S82104B
S82104A
S82105B
Before service, read 119
Before service, read

Preventing personal injury
■ Read the Operator’s Manual before the service work is started.
It is also important to read and follow information and instruc-
tions on plates and decals.
■ Do not wear loose-fitting clothing or jewellery, which can get
caught and cause injury.
■ Always wear a hard hat, protective goggles, gloves, protective
shoes and other protective articles when the work so requires.
■ Make sure that the ventilation is sufficient when starting the en-
gine indoors.
■ Do not stand in front of or behind the machine when the engine
is running.
■ If service work has to be carried out under raised 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 pressurised systems. If a system is opened
without having first released the pressure, liquid under high
pressure will jet out.
S86569
■ When checking for leaks, use paper or hardboard, not your
hand.
■ Make sure that stepping surfaces, handholds and anti-slip sur-
faces are free from oil, diesel fuel, dirt and ice. Never step on
parts of the machine that are not intended for this.
■ It is important to use correct tools and equipment. Broken tools
or equipment should be repaired or changed.
Preventing machine damage
■ When lifting or supporting the machine or parts of the machine,
use equipment with a sufficient lifting capacity.
■ Lifting devices, tools, working methods, lubricants and parts
prescribed in the Operator’s Manual should be used. Volvo CE
will not accept any responsibility otherwise.
■ Make sure that no tools or other objects, which may cause
damage, have been forgotten in or on the machine.
■ Release the pressure in the hydraulic system before starting
the service work.
■ Never set a relief valve to a higher pressure than that recom-
mended by the manufacturer.
■ Machines, which are used within a polluted or in another way
insanitary area should be equipped for this kind of work. Spe-
cial 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 eliminate inter-
ference with the electronic system and components intended
for the function of the machine, see page 10.
■ Measures to be taken in connection with electric welding, see
page 146.
■ Make sure that all covers on the machine are in position before
the engine is started and the machine is put to work.
120 Before service, read
Preventing environmental influence

Be conscious of the environment when carrying out service and
maintenance. Oil and other liquids dangerous to the environment
and released into the environment will cause damage. Oil de-
grades very slowly in water and sediment. One litre of oil can de-
stroy 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 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 environ-
ments 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 handled as waste
dangerous to the environment.
■ Consumables, e.g. used rags, gloves and bottles may also be
contaminated with oils and liquids dangerous to the environ-
ment and must in that case be treated as waste dangerous to
the environment.
Fire prevention 121
Fire prevention
WARNING!
If the machine is used in an environment where the risk of
fire is particularly high, e.g. in explosive environment, spe-
cial equipment is required.
There is always a risk of fire. Find out what kind of fire extinguisher
is used on your working site and how to use it. If the machine is
equipped with a fire extinguisher, it should be kept inside the cab
on the left side of the operator.
If the machine is to be provided with a hand-held fire extinguisher,
it should be of the ABE type (ABC in North America). The designa-
tion ABE means that it is possible to extinguish fires in both solid
organic material and liquids, and that the fire extinguishing com-
pound 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 or have an open flame near a machine when fill-
ing with fuel or when the fuel system is opened and in contact
with the surrounding air.
■ Diesel fuel oil is flammable and must not be used for cleaning.
Use conventional car care products meant for cleaning or de-
greasing. Also bear in mind that certain solvents can cause skin
rashes, damage to the paint finish and constitute fire hazard.
■ Keep the place clean where the service is to be carried out. Oil
and water can make the floor slippery and is also dangerous in
connection with electrical equipment or electrically powered
tools. Oily and greasy clothes are a serious fire hazard.
■ Check daily that the machine and the equipment, e.g. underbel-
ly plates are free from dust and oil. Besides reducing the risk of
fire, it is also easier to detect faulty or loose components.
NOTE! Take great care if a high-pressure wash is used for
cleaning. Electrical components and electrical leads can be
damaged even at a moderately high pressure and tempera-
ture. Protect electrical leads in an appropriate way.
■ Take extra care when cleaning a machine working in a fire-sen-
sitive environment, e.g. 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.
122 Fire prevention
■ 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 incorrect installation
or clamping. This applies particularly to unfused cables, which
are red and marked R (B+) and routed:
– between the batteries
– between battery and starter motor
– between alternator and starter motor
Electrical cables must not lie directly against oil or fuel lines.
■ Do not weld or grind on components which are filled with flam-
mable liquids, e.g. tanks and hydraulic pipes. Exercise care
with such work also in the proximity of such places. A fire extin-
guisher should be kept near to hand.
Actions in case of fire

If the circumstances permit and your own safety is not jeop-
ardised, take the following steps at the slightest sign of fire:
1 Drive the machine to a safe place in order to prevent the fire to
spread.
2 Lower the attachment to the ground.
4 Leave the cab.
5 Turn off the battery disconnect switch.
6 Try to put out the fire. Call the fire brigade if required.
Actions after fire

When handling a machine which has been damaged by fire or
been exposed to intense heat, the following protective meas-
ures must be followed:
■ Use thick, protective gloves made of rubber and wear goggles.
■ Never touch burnt components with your bare hands in order to
avoid contact with melted polymer materials. First wash thor-
oughly with plenty of lime water (a solution consisting of calci-
um hydroxide, i.e. slaked lime in water).
■ Handling heated fluoro-carbon rubber, see page 124.
Handling hazardous materials 123
Handling hazardous materials

Heated paint
WARNING!
All paint decomposes when heated and forms compounds
which may be irritating and after long or frequent exposure
also very unhealthy.
Heated paint gives off poisonous gases. Therefore, paint must be

removed from an area with a radius of at least 10 cm (4 in) before
carrying out welding, grinding or gas cutting. In addition to the
health hazard, the weld will be of inferior quality and strength,
which, in the future, may cause the weld to break.
Methods and precautionary measures when removing paint
■ Blasting
– use respiratory protective equipment and protective gog-
gles
■ Paint remover or other chemicals
– use a portable air extractor, respiratory protective equip-
ment and protective gloves
■ Grinding machine
– use a portable air extractor, respiratory protective equip-
ment 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

Polymer materials can, when heated, form compounds which are
dangerous to health and environment and must therefore never be
burned when scrapped.
If gas cutting or welding is to be carried out near such mate-
rials, the following safety instructions must be followed:
– Protect the material from heat.
– Use protective gloves, protective goggles and respiratory pro-
tective equipment.
124 Handling hazardous materials
Heated fluoro-carbon rubber
WARNING!
Certain seals which are designed to withstand high operat-
ing temperatures, e.g. in engine, main control valve,
hydraulic motor and pumps may be made from fluoro-car-
bon rubber. When heated to high temperatures,
fluoro-carbon rubber decomposes to hydrogen fluoride and
hydrofluoric acid, which is strongly corrosive on skin and
respiratory tracts.
When handling a 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, i.e.
slaked lime in water).
■ The area around 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 sev-
eral years after a fire.
■ If swelling, redness or a stinging feeling appears and one sus-
pects that the cause may be contact with heated fluoro-carbon
rubber, contact a medical doctor immediately. Several hours
may pass, however, before any symptoms appear and there is
no immediate warning.
■ The acid cannot be rinsed or washed off from the skin. Treat in-
stead with Hydrofluoric Acid Burn Jelly or similar before con-
tacting a medical doctor.
Refrigerant
NOTE! All kinds of service on the air conditioning unit must
be carried out by accredited workshops by, or under the guid-
ance of, a person in a leading position with certified compe-
tence.
WARNING!
Refrigerant R134a easily causes frost-bite if it comes into
contact with bare skin. When heated, gases are formed,
which can be harmful to lungs and nervous system.
The air conditioning unit of the machine is filled with refrigerant

R134a at the factory. R134a has no harmful influence on the ozone
layer, but contributes, however, to the greenhouse effect and must
therefore never intentionally be released into open air.
IMPORTANT! R134a must never be mixed with another kind
of refrigerant, e.g. R12, as this leads to a breakdown of the
unit.
Handling hazardous materials 125
In case of contact with escaping refrigerant, the following

measures should be taken:
■ If a leak is suspected, leave the risk area and contact an ac-
credited workshop to get information about measures.
■ The gases formed by heated refrigerant, may be harmful to
lungs and nervous system even at low concentrations when no
smell is apparent. High concentrations have a narcotic effect.
Exposed persons should be remove from the risk area and out
into the fresh air. Seek medical advice, if the symptoms remain.
■ When fluid, the refrigerant may cause frost-bite. Warm carefully
the injured area with lukewarm water or warm clothes. Seek
medical advice, if the symptoms remain.
■ Seek medical advice, if liquid refrigerant has come into some-
one’s eyes.
Batteries
WARNING!
Batteries contain sulphuric acid, which is strongly corro-
sive to skin.
■ Do not smoke near batteries as these give off explosive gases.

■ Make sure that metal objects, e.g. tools, 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, connect the ground cable last in order to re-
duce the risk of sparks.
■ Discarded batteries must be taken care of according to national
environmental requirements.
■ Charging batteries, see page 145.
■ Starting with booster batteries, see page 77.
126 Handling hazardous materials
Crystalline silica (quartz) dust
WARNING!
Avoid exposure to dust containing crystalline silica parti-
cles. This dust can cause serious injury to the lungs (silico-
sis).
Because crystalline silica is a basis component of sand and gran-

ite, many activities at construction sites produce dust containing
crystalline silica. Trenching, sawing and boring of material contain-
ing crystalline silica can produce dust containing that.
If dust which contains crystalline silica is present there are guide-
lines which should be followed.
■ Be aware of the health effects of crystalline silica and that
smoking adds to the damage.
■ Be aware of and follow OSHA (or other) guidelines for expo-
sure to airborne crystalline silica.
■ Know the work operations where exposure to crystalline silica
may occur.
■ Participate in air monitoring or training programs offered by the
employer.
■ Be aware of and use optional equipment controls such as water
sprays, local exhaust ventilation, and enclosed cabs with posi-
tive pressure air conditioning.
■ Where respirators are required, wear a respirator approved for
protection against crystalline silica-containing dust. Do not alter
the respirator in any way. Workers who use tight-fitting respira-
tors cannot have beards/mustaches which interfere with the
respirator seal to the face.
■ If possible, change into disposable or washable work clothes at
the work site ; shower and change into clean clothing before
leaving the work site.
■ Do not eat, drink use tobacco products, or apply cosmetics in
areas where there is dust containing crystalline silica.
■ Store food, drink and personal belongings away from the work
area.
■ Wash hands and face before eating, drinking, smoking, or ap-
plying cosmetics after leaving the exposure area.
127

If the machine is to function satisfactorily and at lowest possible
cost, it requires careful maintenance.
Lubrication and service chart

The section “Lubrication and service chart” describes the mainte-
nance work, which the operator can carry out. If certain operations
require trained workshop personnel and special equipment, this
will be indicated.
Service history
After each completed service at a workshop authorised by Volvo
CE, the service history should be filled in, see page 188. Service
history is a valuable document, which can be referred to when for
example selling the machine.
Arrival and Delivery Inspections

S86524
Before the machine leaves the factory, it is tested and adjusted.
The dealer must also, if the warranty is to apply, carry out "Arrival
and delivery inspections" according to applicable form, which must
be signed.
SERVICEEPPROGRAMME
Excavators B-Models
Volvo CE, Korea Construction Equipment
Delivery Instructions
Machine Type Ser. No. Operating Hours Delivery Date Page
1 (5)
Owner Date Dealer
The Service Programme is to be used as a check list in connection with Warranty Inspections and maintenance.
Sign.
When handing the machine over, the dealer must give the buyer
DELIVERY
INSTRUCTIONS
Please pay attention to safety and environmental instructions in Operator s and Service Manu-
als for the machines concerned.
See the Service Guide regarding specifications and the Operator s Manual for information regarding checks and changes/
replacements.
"Delivery instructions" according to applicable form, which must be
Machines manufactured by Construction Equipment
signed, if the warranty is to apply.

First First Daily Every Every Every Every Every NOTE:
Volvo Construction Equipment OPERATING HOURS / INTERVAL 100 1000 50 250 500 1000 2000
Machine model Serial no. A = Warranty inspection

Owner Customer no. Page
B = Maintenance 1 (2)
A A B B B B B B
Operator (Recipient)
1 General
Delivery instruction carried out on the
1:1
Test-run the machine and check:
The inspection programme Deliver y Instructions is to be used for checking the machine with the customer/owner and for presenting the
machine to the customer/owner. l amps
instruments and controls
starter inhibitor
Please pay attention to the safety and environmental instructions in Operator•s and Service Manuals for
the machines concerned.
Steering system
Brake system (service brakes)
Service Programmes
Retarder
Performing, signing and submitting the delivery instructions parkingisbrake
a pre-condition for a valid
ARRIVAL
L AN
AND machine warranty. differential locks and 6-wheel drive Performed
DELIVERY INSPECTION 1 Check together with the owner/operator that the delivered tipping function
machine corresponds to the order.
Machines manufactured by Construction Equipment machine for external damage
Volvo Construction Equipment 2 Presentation of the machine including optional equipment.
1:2 Lubrication, see Lubrication and service
Machine Model Serial no. Operating hours Arrival date Delivery date chart.
Page
1 (2)
Review of the Operator s Manual with emphasis on the following points.
1:3 Check for fuel, coolant and oil leaks.
(Depending on machine type, certain points are omitted.) Performed
The Service Programme should be used in connection with war-

Arrival inspection by Delivery inspection by Dealer
3 Operation 1:4 Check:

The inspection programme Arr ival and Delivery Inspection is to be used as a check on a machine upon its arrival from the factory and for an
bolted joints
inspection before its delivery to the customer. Running-in instructions.
tyre pressure
Ca b, instruments and operating controls. clearance at dump body frame (between
Please pay attention to the safety and environmental instructions in Operator•s and Service Manuals fordump body and frame).
the machines concerned.
Arrival inspection
The arrival inspection is the first check of the product Tafter
Co ntronic functions.
S tart/stop, warming up.
ransmission,
transport. shifting gears.
1:5 Replace breather filters for brake cooling oil
tank, fuel tank, hydraulic tank, transmission,
dropbox and drive axles. Intervals between
Performed
changes, see the respective Operator s
ranty inspections and during maintenance carried out by a work-
Manuals.
shop authorised by Volvo CE.

1 Any deviations or transport damage must be reported Re tarder
to thefunction.
carrier, and then immediate correc-
tive actions must be taken. 2 Engine
Service brakes and parking brake.
2 Check that the machine is equipped according toSthe order confirmation,
teering, and that tools and man-
secondary steering. 2:1 Check freezing point of coolant.
uals are supplied with the machine. Any deviations should be reported to the sales department.
Operator environment, heating, ventilation and 2:2 air Check/adjust
conditioning. valve clearance. D9/D12
3 Check that no caps for the oil filler points, fuel tanks, radiator or expansion tank are missing, in every 4000 hours.
incorrect position or broken. When applicable, check that no caps
Attachment for the
bracket brake, clutch
(attaching fluid reser-and use of attachments.
an attachment)
The intervals recommended between checks, oil changes and lu-

voirs and washer fluid are missing. 2:3 Check water trap, fuel system.
Lo ading, digging, dumping, lifting and grading operations.
4 As soon as possible after the machine has been transported it should be washed with fresh water.
Operation on a public road.
5 After the inspection, the anti-corrosion treatment of the machine should be renewed. If it is to be
T owing.
stored again for a longer period, follow the instructions in "MAINTENANCE OF STORED Volvo Construction Equipment Customer Support AB Please send comments about the Service Programme to
brication apply provided that the machine is used under normal en-
SE-631 85Eskilstuna sp@volvo.com
MACHINES". T yre pressure. Sw eden
Delivery inspection 4 Service, maintenance

The delivery inspection is a check before the product is delivered to the customer. Performed
Engine, cooling system and fuel system.
6 Check the engine coolant level and the oil level in the engine, transmission, axles and hydraulic
vironmental and operating conditions.

Electrical
system. Check the freezing point of the coolant. When system including
applicable, check thebattery
level instate of charging
all brake fluid and starting with booster batteries (jump start-
ing).washer system. See the Operator s Manual.
reservoirs. Check the water level in the windscreen
Note: Do not start engine with battery charger connected.
7 Remove transport protection from the hydraulic cylinders.
Power transmission / axles.
Clean any anti-corrosion agent from the piston rods.
8 Check and adjust tyre pressure or on excavatorsBrake

checksystem.
the track slack adjustment.
9 Start the engine and run the machine until normal operating temperature has been reached.
Check that the following systems function normally:
Volvo Construction Equipment Customer Support AB Please send comments about the Inpection Programme to
Electrical system: Check that instruments,SE-6
control lamps
31 85Esk ilstunaand other lights are working. sp@volvo.com
Sw eden
Brake system: Test the service brakes, parking/emergency brakes and engage the retarder
(where applicable).
S teering system: Turn the steering wheel to both full steering lock positions. When applicable,
check electrical secondary steering function. On Motor Graders, lean the front wheels left and
right.
Hydraulic system: Run all hydraulic cylinders to their respective end position.
Check all equipment and functions.
10 Check that there are no fuel, water or oil leaks. If necessary, check-tighten connections, clamps
and fittings.
Warranty Inspection
11 Any malfunctions or defects must be corrected, noted and reported to the supervisor.
See page 2.
12 Turn off the battery disconnect switch.
Volvo Construction Equipment Customer Support AB

SE-631 85Eskilstuna
Please send comments about the Inspection Programme to
sp@volvo.com S86570
Two Warranty Inspections should be carried out by a workshop au-
thorised by Volvo CE. The first within 100 operating hours and the
Sw eden
second at the latest at 1000 operating hours.

The carrying out of these warranty inspections is a condition for the
warranty to apply.
At these inspections there are, among other measures, oil and flu-
id changes, which must be carried out before the ordinary inter-
vals.
Maintenance
Regarding intervals for other maintenance, see the “Service Pro-
gramme” or the Lubrication and Service Chart in this chapter.
128
Cleaning the machine

The machine should be cleaned regularly with conventional car
care products in order to eliminate the risk of damage to the paint
finish and other surfaces on the machine.
IMPORTANT! Avoid using strong cleaning agents or chemi-
cals in order to minimise the risk of damage to the paint fin-
ish.
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 121.
Recommendations for cleaning the machine
– Place the machine in a place intended for cleaning.
– Follow the instructions supplied with the car care product.
– The water temperature must not exceed 60 °C (140 °F).
– If high-pressure wash is used, keep a distance of at least
20–30 cm (8–12 in) between nozzle and machine surface. Too
high push and too short distance may cause damage. Protect
electrical leads in an appropriate way.
– Use a soft sponge.
– Finish by rinsing the whole machine with only water.
– Always lubricate the machine after washing.
– Touch-up the paint finish when required.
Paint finish maintenance
– Machines which are used in corrosive environment suffer more
from rust that others. As a preventive measure it is recom-
mended 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 mudguards where mechanical wear
is expected.
Touching up paint finish
– Check if there are any damaged areas of the paint finish.
– At first clean the machine.
– Rectify any damage to paint finish in a professional way
129
Cleaning engine compartment

Machines operating in dusty environment or environment exposed
to fire hazards e.g., 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.
WARNING!
The engine must not be running when cleaning as rotating
parts may cause injuries.
Loose material is removed 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
130 Service points
Service points
3 6
1 2 4 5 7 8 9
10
11
12,13
14
18 17 16 15
19
20 21 22 23 24 25
28
S83412
16 27 26
1 Airconditioner filter 15 Track motor oil, level checking

2 X1 filter 16 Hydraulic oil, draining
3 Battery disconnect switch 17 Hydraulic tank suction strainer
4 EDB(Electrical distribution box) 18 Battery
5 Hydraulic oil, level checking 19 Coolant, level checking
6 Hydraulic oil, filling 20 Coolant, filling
7 Hydraulic oil return filter 21 Engine oil, filling
8 Hydraulic tank breather filter 22 Engine oil, checking
9 Hydraulic oil drain filter 23 Aircleaner filter
10 Hydraulic oil pilot filter 24 Fuel tank breather filter
11 Engine oil filter 25 Fuel, filling
12 Fuel filter 26 Fuel, level checking
13 Water separator 27 Fuel, draining
14 Engine oil, draining 28 Coolant, draining
Engine 131
Engine
Engine oil level, checking
Check the oil level when the central warning lamp blinks and
the buzzer sounds. Aside from this, check the oil level every
A B day.
1 Open the engine hood.
2 Pull out dipstick (A) and wipe it with a clean cloth.
3 Push it in and pull it out again.
4 If the oil level is between C and D, it is normal. If the oil level is
below D, refill to proper oil level through filler port (B). For the
recommended engine oil, see page 165.
Engine oil, changing
WARNING!
S83416
Take care when changing oil, as hot oil can cause burns on
unprotected skin.
MAX
C
Change the oil every 500 hours when CI-4 class is used.
MIN
D
The conditions for the 500 hours interval between oil change
A Dipstick are that:
B Filler port – The oil filters should be replaced every time the oil is changed.
C Oil level, High – The oil filters are genuine Volvo filters.
D Oil level, Low – The sulphur content in the diesel fuel must not exceed 0.3 per-
cent by weight.
– The oil used is of a certain quality grade, see page 165.
– The correct oil viscosity for the ambient temperature is select-
ed, see page 165.
If any of these conditions cannot be met, or if the machine is
operated in an acid or particularly dusty environment, the oil
should be changed and the filters replaced more often. Con-
tact Volvo CE dealer.
– If sulphur contents >0.5 % then 125 hours drain interval must

be practiced.
– The oil must be changed at least every 6 months, regardless of
the operating hours.
– If the oil grade is lower than ACEA-E3 or API CE, 125 hours
drain interval must be practiced.
– Oil grade lower than ACEA-E2 or API CD must not be used.
– Oils that meet only API CF-4 must not be used.
132 Engine
Engine oil, draining

1 Place the machine in the service position.
2 Loosen the bolt and nut (G) to open the cover (H).
3 Put a container (above 50 liter, 13 US gal.) under the protecting
cap (E) at the bottom of the engine oil pan.
4 Open the filler cap.
5 Remove protecting cap (E) and attach drain hose (F) provided
as a service tool with machine.
6 Drain the oil.
IMPORTANT! Take care of filters / oils / liquids in an environ-
E mentally safe way.
7 Disconnect the hose and install the protecting cap.
S83445 8 Fill the oil through the oil filler cap.
G H F
Oil capacity for changing, see page 167.
Engine oil filter, replacing

Replace the oil filters every time the oil is changed.
The oil filters are the disposable type, i e. they cannot be cleaned,
but should be replaced.
Removing
1 Using a suitable tool, remove filters.
Installing
2 Fill filters with oil.
Oil capacity of each filter is approx. 1.25 liter (0.33 US gal).
3 Coat the gasket with oil.
4 Screw on the filter by hand until the gasket just touches the
sealing surface.
5 Tighten the filter a further 1/2 turn.
After installing
6 Start the engine and check that the gaskets are sealed. If not,
remove the filter and check the sealing surface.
S83417
IMPORTANT! It is important that the filters are filled with oil

before it is installed. This is to ensure lubrication of the
engine immediately after starting.
IMPORTANT! Run the engine at low idling for at least one
minute after replacing oil filters,.
Valve clearance, adjusting

Check the valve clearance every 4000 hours.
The work should be carried out by a workshop authorized by Volvo
CE.
Fuel system 133
Fuel system
Clean fuel is essential for trouble-free of the diesel engine.
Fuel, filling
B
WARNING!
A
Stop the engine when refuelling.
WARNING!
The engine heater must not be switched on when filling
fuel. There is a risk of fire and explosion with possible
injuries as a consequence.
S83446
A Fuel level gauge

1 Carefully clean around the filler cap on the fuel tank before re-
moving it.
B Fuel filler cap
2 Open the fuel filler cap.
3 Fill the fuel in the tank watching the fuel level gauge.
Avoid spilling the fuel when filling, which attracts dirt. During the
cold season, keep the tank full to prevent water condensing in the
tank.
For the capacity of fuel tank, see page 167.
For fuel quality, see page 165.
NOTE! Be careful not to damage the level gauge on the fuel
tank by being stained from thinner or oil.
Filling with auto shut-off controller (optional

equipment)
This pump is provided with an electronic overfilling protection.
1 Connect the pump hose with strainer in the fuel barrel.
A 2 Press the green start button (C). The pump will run as long as
the tank is not full.
B – At any time during the refuelling or when the drum has
been emptied, the pump may be stopped by pressing the
ITT Jabsco red button (D).
– The pump will automatically stop when the fuel level sen-
STOP
START
sor is actuated.
The pump cannot be restarted until the fuel from the tank
is used.
S83418 IMPORTANT! Never let the fuel filler pump idle. The pump
C D may be damaged.
A Fuel filler pump hose
B Fuel filler pump
C Start button (green)
D Stop button (red)
134 Fuel system
Fuel tank, draining

Drain the sediment every 100 hours.
1 Open the drain valve (B) at the bottom of the tank.
2 Open the filler cap.
3 Connect the drain hose (F) and drain off any sediment.
4 Disconnect the drain hose and install the valve again.
5 Close the filler cap.
S83419
B Drain valve
F Drain hose
Fuel main filter, changing

Replace the fuel filter every 500 hours.
If using fuel of lower quality, replace the filter more often.
The filter is the disposable type, i.e. it cannot be cleaned but
must be replaced.
Removing
1 Use a suitable tool for removing fuel filter.
Installing
2 Coat the gasket with diesel fuel.
3 Screw on the filter by hand until the gasket just touches the
S83420 sealing surface.
4 Then tighten the filter a further 1/2 turn.
B A
NOTE! Automatic deaeration system is applied that there is
A Water separator no need to bleed the air after changing the filter.
B Fuel main filter
Fuel system 135
Water separator, draining

The water separator is designed to remove the water from the fuel
supplied to the engine.
Check and drain the water in the water separator when there
is an indication on the instrument panel (central warning lamp
blinks and the buzzer sounds).
A
1 Place a vessel under drain hose.
B 2 Open the drain valve (C) and drain the water.
C
D Water separator element, changing
S83447
Change the water separator element every 500 hours.
A Filter element 1 Place a vessel under drain hose.
B Bowl 2 Open the drain valve and drain the fuel in the water separator.
C Drain plug IMPORTANT! Take care of filters / oils / liquids in an environ-
D Sensor connector mentally safe way.
3 Disconnect the sensor connector (D).
4 Remove the filter (A) including the bowl assembly (B) with sen-
sor and drain plug (C). Wipe up all spilled fuel.
5 Remove the bowl assembly and set it aside for reinstallation.
6 Check the condition of the O-ring. Replace the O-ring if dam-
aged.
7 Carefully install the bowl assembly with the new filter. Tighten
it with hand only.
8 Clean the mounting surface of element, fill with fuel in the filter
and apply a small amount of fuel to the gasket of the new filter.
9 Install the new filter until it contacts the mounting surface.
Tighten the filter and bowl.
10 Reconnect the sensor connector (D).
Fuel system, air bleeding

If the fuel system has been run dry or if air has got into the system
because of any reasons, the air in the system must be bled out.
B IMPORTANT! Do not attempt to start the engine under any
circumstances until the air in the system has been bled out
completely, otherwise the injection pump can be seriously
damaged.
NOTE! Do not spill fuel on electrical components.
1 Actuate the hand feed pump (B) until there is a resistance in the
hand pump.
2 Start the engine and let it run in idle for 3 minutes.
3 If the engine is difficult to start, repeat (1) to (2).
S83448
4 Check for leakages.
136 Intercooler
Air ventilation filter on fuel tank, changing

3 Change the air ventilation filter every 2000 hours.
2 4
1 The filter is the disposable type, i.e. it cannot be cleaned, but
must be replaced.
1 Disassemble the protection cover (3) after loosing 2 screws (1).
2 Remove the air ventilation filter (4) after loosing a clamp (2).
3 Replace the air ventilation filter (4), then tighten the filter (4)
with clamp (2).
4 Assemble the protection cover (3) and tighten 2 screws (1).
S83449
1 Screws
2 Clamp
3 Protection cover
4 Ventilation filter
Intercooler
The engine is provided with an air-to air type intercooler. The inter-
cooler lowers the temperature of the induction air. The induction air
then becomes more dense, so that more fuel can be injected and
combusted. This will result in a higher engine output, but the colder
air also leads to less stress on valves and pistons.
Turbocharger
IMPORTANT! Leave the engine running at low idling speed
for at least half a minute after start and a few minutes before
it is stopped. This is to safeguard the lubrication of the turbo-
charger.
The turbocharger is lubricated and cooled through the engine lu-
brication system. A vital condition for the function of the turbo-
charger is that the engine oil is changed and the filters are
replaced at prescribed and regular times. The maintenance of the
air cleaner, the tightness of the exhaust system and the lubrication
lines are also important for the function.
If any jarring noises can be heard or if the turbocharger vibrates, it
must be reconditioned or changed immediately.
A Exhaust in Only an authorized dealer workshop may carry out work on

B Exhaust out the turbocharger.
C Air in
D Air out
Air cleaner 137
Air cleaner
The air cleaner prevents dust and other impurities from entering
the engine. The air first passes through the primary filter and then
the secondary filter.
The degree of engine wear depends largely on the cleanliness of
the induction air. Therefore, it is very important that the air cleaner
should be checked regularly and maintained correctly. Observe
great cleanliness when working with the air cleaner and filters.
IMPORTANT! Do not, under any circumstances, run the
engine without a filter or with a damaged one.
Check regularly that hose and pipe connections from the air clean-
er to the engine induction manifold do not leak.
Always have an air filter at hand as a spare one and keep it
well protected from dirt.
Primary filter, cleaning and changing

Clean the filter when the warning lamp in the instrument panel
is ON. The filter may be cleaned, at the most, six times. There-
after, the filter should be replaced and at least every 1000
hours. Also replace the filter if it is damaged
If the control lamp is still alight after replacing or cleaning the pri-
mary filter, the secondary filter must be replaced.
As the length of time between filter replacements depends entirely
on the operating environment of the machine, it may sometimes be
S86197 necessary to replace the filter more often.
Mechanical cleaning
1 Open the cover.
2 Press with both thumbs on primary filter (B) at the same time as
you pull it out. This is to prevent the secondary filter from com-
ing out together with the primary filter.
3 Carefully tap the end of the primary filter against a soft and
clean surface.
NOTE! Do not tap against a hard object.
Cleaning with compressed air
S83421 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
C
cm(1~2 in).
B
2 Blow the filter from the inside along the folds.
Checking filter
1 Check the filter with the aid of a lamp.
A
2 If there is the smallest hole, scratch, crack or other damage,
the filter must be discarded.
NOTE! To discover the damage more easily, this check should
be made in a darkened room.
S80710
138 Dry type precleaner (optional equipment)
Secondary filter, changing

C Replace the secondary filter when necessary, or if the warn-
B ing lamp is still alight even though the primary filter has been
cleaned or replaced.
The secondary filter (C) works as a protective filter in case the pri-
mary filter should be damaged.
S82216A NOTE! The secondary filter must always be replaced, never
A cleaned.
Never remove the secondary filter unless it is to be replaced.
1 The secondary filter should be removed carefully and with pre-
cision so that no impurities enter the engine.
2 Carefully check that the new secondary filter is correctly in-
stalled.
Dry type precleaner (optional

equipment)
This precleaner is connected on the aircleaner instead of raincap,
A which has a scavenger tube attached to the muffler
B This precleaner has functions;
C – Precleaning the largest contaminants by basket screen (B)
D – Separating and ejecting the debris by the impeller in the top of
precleaner.
E F – Self-cleaning through scavenging line (E) by exhaust system.
G If there is problem in those functions, follow the appropriate in-

structions listed below.
1 Remove the scavenger tube from the body.
S83487
2 Start the machine and run until it reaches high Idle. While at
high idle, use a piece of notebook paper to cover the opening
of scavenger tube. If the paper is held in place, then the vacu-
A Precleaner
um is acceptable.
B Basket screen
3 Turn the machine off, and then shake the check valve to verify
C Cone adapter
that the flapper is loose (will rattle). If the flapper is loose and
D Body
the vacuum on the scavenging tube is acceptable, then pro-
E Scavenging line
ceed to step 6.
F Check valve
4 If the vacuum is not present on the scavenging line, check the
G To muffler
line to make sure nothing is blocking the airflow. If the scaveng-
ing line is clear then remove the line from the muffler.
5 Check the vacuum at the scavenging line connection at the
muffler. If there is still no vacuum then the muffler must be
checked.
Dry type precleaner (optional equipment) 139
6 Loosen the clamp and separate the cone adapter from the main
body. Lay the upper portion of the assembly down in safe place
B for inspection. Inspect the main body for debris. Clean the
catch tray and scavenger port outlet if debris are present,
A 7 Re-install the scavenger tube to the scavenger port outlet on
the side of the body after cleaning. Compressed air is recom-
mend to clean out the catch tray and scavenger port outlet.
8 After inspection of the body, the precleaner needs to be in-
spected as well. In order to inspect the precleaner, turn the as-
C sembly that was previously removed upside down. Reach
S85623 down inside and spin rotor assembly with your hand.
A Scavenging port
B Body
C Debris catch tray WARNING!
The stop tabs on the inside throat of the precleaner can be
sharp. Careless treatment can cause the injury.
9 If rotor spins freely, turn the assembly over and blow out the
ejection port with compressed air.
WARNING!
Personal injury may occur if compressed air is used to spin
rotor.
10 Clean any debris off of the basket screen with compressed air.
11 Reassemble the all units in the reverse order of the instruction
steps above, then start the engine and run the engine at high
idle. Check ejection duct on precleaner for positive pressure
with a piece of notebook paper. If paper blows away from the
precleaner then it is operating properly.
140 Cooling system
Cooling system
IMPORTANT! If the warning lamp for high coolant tempera-
ture lights up and the buzzer sounds, the engine should be
stopped immediately.
IMPORTANT! Cooling system is so sensitive that the coolant
with different properties should not be blended. For the cor-
rect coolant fluid, see the label on the expansion tank.
S83488
IMPORTANT! The Volvo genuine coolant VCS must be used.
Radiator, oil cooler and condenser fins,

cleaning
Clean all fins every 500 hours.
If the engine temperature becomes too high even though the cool-
ant level is correct, the radiator should be cleaned.
WARNING!
Compressed air, steam or water can cause personal injury.
Wear safety goggles or a face mask. Do not use steam to
clean the condenser of air conditioner.
1 Remove any mud, dust or leaves attached to the radiator fins
and oil cooler fins with compressed air.
2 Clean the radiator, charged air cooler and oil cooler with com-
pressed air after detaching the clogging nets.
3 Check the rubber hose for wear and cracks. If damaged, re-
place it. Check the hose clamp for looseness.
4 Reinstall the nets.
IMPORTANT! When using compressed air, keep the nozzle at
a distance from the fins to prevent a damage. If the fins are
damaged, this may cause leakage or overheating. Under
dusty environment conditions, check it every day regardless
of the maintenance interval.
If the engine temperature still remains high after cleaning the cool-
er, contact a workshop authorized by Volvo CE for remedial action.
Coolant properties, checking

Check the coolant properties every 500 hours.
When the machine is delivered from the factory, the cooling sys-
tem is filled with a mixture of tap water and concentrated Volvo
Construction Equipment anti-freeze, which lowers the freezing
point and raises the boiling point of the coolant.
The Volvo genuine concentrated anti-freeze also contains active
anti-corrosion additives in order to protect the engine and radiator.
These additives have a limited durability.
NOTE! The Volvo genuine anti-freeze must not be mixed with
any anti-freeze or additives of another maker. The mixing may
have a negative effect.
The anti-freeze content must not be less than 40%.
40% lowers the freezing point to -25 °C (-13 °F).
Cooling system 141
Coolant level, checking

B
Check the coolant level daily.
WARNING!
Immediately after operating the engine, the coolant is very
hot. Do not open the radiator cap until it has cooled down.
After cooling it, open the cap slowly to release the internal
A pressure.
1 Check the coolant level after opening the cover (B).
S83450 2 If the coolant level is lower than “MIN” marking on the tank, top
up the coolant through filler cap (A) more than “MIN” level.
MIN
Coolant, changing
Change the coolant every 6000 hours.
IMPORTANT! The Volvo genuine anti-freeze must not be
mixed with any anti-freeze or additives of another maker. The
mixing may have a negative effect.
WARNING!
Take care when replacing the filter. Hot coolant can cause
severe burns on unprotected skin.
Draining
1 Remove the radiator bottom cover and put a container under
drain cock (C).
2 Loosen the expansion tank cap (A)
3 Open the cock (C).
C NOTE! The cooling system does not become safe against
frost even after draining. There may be pockets of water left.
IMPORTANT! Take care of filters / oils / liquids in an environ-
mentally safe way.
Flushing
4 After draining, close the cock (C).
S83423 5 Refill the coolant through the expansion tank cap with clean tap
water and close the tank cap.
6 Start the engine and run at low idle for about 10 minutes.
7 Stop the engine and drain the water.
142 Cooling system
Filling
1 After flushing, close the cock (C) and remove the cap (A).
2 Fill the recommended coolant through the cap (A).
3 Run the engine at low idle for about 5 minutes.
4 Stop the engine and refill the coolant to the proper level on the
expansion tank.
5 Install the expansion tank cap.
For the capacity of cooling system, see page 167.
IMPORTANT! Never fill cold coolant in a warm engine. This
can cause cracking in the cylinder block and cylinder head.
Failure to change coolant will cause clogging of the cooling
system and the risk of the engine seizing.
Fan belt tension, checking

Check the belt every 500 hours.
A
WARNING!
The engine must be stationary when checking the belt
tension. Rotating parts can cause injuries.
B
At correct belt tension, it should be possible to depress the
belt approx. 15 mm (0.6 in). If above 15 mm, replace the belt
C with a new one
D
E
F S83471
A Fan pulley
B Water pump pulley
C Auto tensioner
D Belt
E Idler
F Crankshaft pulley
Electrical system 143
Electrical system
Battery disconnect switch
IMPORTANT! The battery disconnect switch must always
remain turned on while the engine is running.
If it is turned off while the engine is running, the electrical
system may be damaged.
Battery disconnect switch (A) is located on the electrical distribu-
tion box which is located on rear side of cabin.
When welding, servicing of electrical system or after finishing work
of the day for safety, the battery disconnect switch should be
turned off.
Relays and slow blow fuse

The machine has an electrical distribution box. The electrical dis-
tribution box contains relays and slow blow fuses.
When current with large capacity flows, the slow blow fuse protects
components, which allow them to operate until the overload caus-
es a circuit disconnect. When current with small capacity flows, it
is fused slowly enough to solve the inconvenience of frequent fuse
replacement.
If the electrical system does not work after repairing the electrical
system, check these slow blow fuses.
4 5, 6
7
3
8
2
9
1 10
11
12
13
S83424
1 Battery relay 6 Wiper controller 11 Circuit breaker fuse(80A)

2 Pre heater relay 7 Fuse box 12 Circuit breaker fuse(40A)
3 Safety relay 8 Fuse box 13 Battery disconnection switch
4 DC-DC Convert 9 Relay box 14 Connector
5 DC-DC Convert 10 Circuit breaker fuse(150A)
144 Electrical system
Fuse box
The machine has a fuse box installed in the electrical distribution
box. This box contains most of the fuses of the machine.
WARNING!
Never install a fuse with a higher ampere rating than that
stated on the decal (risk of damage or fire on the circuit
board).
S83451
Fuses are easily accessible after discovering the cover of fuse
box. A decal which shows the exact positions and specifications of
respective fuses is provided on the inside of cover, see page 170.
NOTE! If a fuse blows repeatedly in the same position, the
cause of the fault has to be investigated.
Batteries, rules
See page 125.
Battery electrolyte level, checking

Check the electrolyte level every 250 hours (more often at
temperature above +15 °C = +59 °F).
WARNING!
Battery gas (hydrogen) is flammable. Do not expose to
sources of fire such as open flame, cigarettes or sparks.
1 Open the cover of the battery box on the right side of the ma-
chine after taking off the bolts (B).
2 Loosen the cap (A)
The electrolyte level should stand approximately 10 mm (0.4
A
in) above the cell plates.
3 Top up with distilled water when required.
4 Operate the machine after toping up, so that the water is mixed
in with the battery electrolyte. This is more important in cold
weather.
S83452 5 Check that cable terminals and pole studs are clean, well tight
B end and coated with petroleum jelly or similar.
Electrical system 145
Battery, charging
WARNING!
During rapid charging of batteries, always remove the cell
caps. When a battery is being charged, an explosive
mixture of oxygen and hydrogen gas are formed. A short
circuit, open flame or a spark near the battery can cause a
powerful explosion.
– Always turn off the charging current before the charging lead
clips are removed.
– Ventilate well, especially if the battery is charged in a confined
space.
S80651A
– The battery electrolyte contains corrosive sulphuric acid. Any
electrolyte that is spilled on the skin should be removed imme-
diately. Wash with soap and plenty of water. Should you get
splashes of electrolyte in your eyes or on any other sensitive
part of your body, rinse immediately in plenty of water and con-
tact a doctor immediately.
Alternator and compressor belt tension,

checking
Check the belt tension every 500 hours.
WARNING!
The engine must be stationary when checking the belt
A tension. Rotating parts can cause injuries.
B Checking
C Press the center between the compressor and the alternator pulley
D with a force of 12 kgf. If the slack is about 10 mm, the tension is
normal.
E
Adjusting
The belt tension will be adjusted automatically by the auto tension-
er.
S83472 If the belt tension is abnormal, check for damage of the auto ten-
sioner or belt specification.
A Alternator The alternator installation is sensitive to incorrect connection,
B Auto tensioner therefore always follow the instructions below:
C Belt – Battery and alternator cables must not be disconnected while
D Compressor the engine is running. A fault may then arise in the alternator
E Crankshaft pulley and the electronics.
– Disconnect and insulate the battery cables before carrying out
any work on the alternator equipment.
– The battery terminals must never be confused. Each terminal is
clearly marked with a (+) or a (-) sign respectively. If the cables
are wrongly connected, the alternator rectifier will be ruined im-
mediately.
– When disconnecting batteries, first break the circuit using the
battery disconnect switch. See page 143.
146 Air conditioner
Electric welding
– Before electric welding is carried out on the machine or any at-
tachment installed to the machine, the current must be
turned off at the battery disconnect switch.
– Before carrying out any electric welding on the machine, the
battery cables should be disconnected and the connectors
pulled out of the electronic control units.
– When disconnecting and reconnecting, the leads should not
have current (turn off the battery disconnect switch).
– Connect the earth (ground) lead of the welding equipment as
close to the welding point as possible.
– Before welding, remove all paint from an area of at least 10 cm
(4 in) around the welding point. Paint which is heated gives off
unhealthy gases.
– All paint decomposes when heated and forms a great number
of compounds, which may cause irritation and be dangerous to
one’s health after repeated or prolonged exposure.
– In addition to the health hazard, the weld will be of inferior qual-
ity and strength, which in the future may cause the weld to
break. Therefore never weld directly on a painted surface.
Air conditioner
Clean the prefilter every 500 hours and main filter every 1000
hours. Replace them every 2000 hours.
If the air conditioner filter is clogged, the air flow will be reduced as
well as the cooling and heating capacity. Therefore, clean it peri-
odically.
IMPORTANT! The system contains HFC (R134a) under pres-
sure. By law, HFC must not be deliberately released. Repairs
A and re-filling of the refrigerant system must only be done by
trained personnel. Contact a workshop authorized by Volvo
S83453 B
A CE.
E C
D Air conditioner filter, cleaning
1 Unscrew the bolts (A).
2 Pull the filter lever (B) on the prefilter (C)
3 After opening the 4 latches, open the cover (D) and take out the
main filter.
4 Clean the filter with compressed air.
5 If the filter is damaged or heavily contaminated, replace it with
a new one.
6 Install the filters, and assemble them in reverse order.
Hydraulic system 147
Hydraulic system
IMPORTANT! Any work on the system requires great
demands on cleanliness. Even very small particles can
cause damage or clog up the system. Therefore, wipe areas
in question clean before any work is carried out.
Hydraulic oil level, checking

Check the oil level daily
1 Park the machine in service position B. See page 117.
S82227 2 Move the control lock-out lever down to lock the system secure-
ly and stop the engine.
3 Move the left and right operating lever with full stroke in all di-
rections to release internal pressure trapped in the hydraulic
circuits.
4 Open the side door on the right side of the machine and check
the oil level in the sight gauge.
– If the level is in the center of the gauge, the level is correct.
– If the level is low, open the cover on the tank and add hy-
draulic oil.
S83425
Hydraulic oil, changing
Change the hydraulic oil every 2000 hours
B
WARNING!
A Take care when changing oil. Hot oil can cause burns on
C unprotected skin.
D 1 Swing the superstructure so that drain plug (F) at the bottom of
the hydraulic tank is located between the left and right tracks.
2 Extend the bucket cylinder completely, retract the arm cylinder
completely and lower the boom to the ground.
S83454
3 Move the control lock-out lever down to lock the system secure-
ly and stop the engine.
4 Release the internal pressure of the tank through air breather
(A).
5 Open the cover (B) after removing the screws (E).
6 Remove O-ring (C).
7 Place a container under the hydraulic tank.
F 8 Loosen the bolts (H) and open the cover (I). Remove the pro-
tecting cap for drain plug (F) and attach drain hose (G), which
is the same hose as that used for draining engine oil.
I
9 Drain the oil.
H H IMPORTANT! Take care of waste oil/liquids in an environmen-
G tally safe way.
S83489
148 Hydraulic system
10 Disconnect the drain hose and install the protecting cap.

11 After cleaning the magnetic rings of strainer thoroughly, rein-
stall it.
12 Fill oil and re-install the cover.
13 Check the oil level in the sight gauge.
14 If the oil level is correct, close the bottom cover (I) and tighten
the bolts (H).
For the information of oil capacity when changing, see page 167.
For oil grade, see page 165.
NOTE! When changing from a mineral oil to a bio oil, please
contact the workshop authorized by Volvo CE.
Hydraulic oil return filter, replacing

Replace the return filter after first 250 hours and then every
1000 hours.
A B
WARNING!
C
Release the internal pressure of the tank before removing
cover.
1 Place the machine in service position B.
2 Unscrew the bolts (B) and remove the cover (A).
D 3 Remove O-ring (B), spring and bypass valve (C), and then pull
out the filter (D).
4 Clean the dismantled parts.
5 Install a new filter and all parts.
When mounting the cover (A), fasten the bolts while pressing
down the cover.
S80434A 6 Run the engine at low idle speed for 10 minutes to remove the
air.
7 Stop the engine.
Hydraulic drain filter, replacing

Replace the cartridge for the drain filter after first 250 hours
and then every 500 hours.
1 Place a container under the drain filter, and turn the filter coun-
terclockwise to remove it.
2 Fill the new filter with oil, thinly coat O-ring with oil.
3 Install the new filter.
S83426
Hydraulic system 149
Pilot filter, replacing

Replacing the element in the pilot filter after first 250 hours
and then every 1000 hours.
1 Place a container under the filter.

2 Remove the filter bowl.
3 Replace the inner element of the pilot filter.
4 Reinstall the filter bowl.
S83427
Strainer, cleaning and changing

Clean the strainer every 2000 hours and change it when nec-
essary or damaged.
E
B
1 Place the machine in service position B.
A
2 Press breather (A) to release the internal pressure at the tank.
C 3 Remove the cover (B) and pull out strainer (D).
D 4 Clean or replace the strainer according to operating hours.
5 Reinstall the cover.
S83454
Air breather filter on hydraulic tank, replac-

ing
Replace the element in the air breather every 2000 hours or
when necessary.
NOTE! The filter cannot be cleaned but must be replaced.
A In dusty working environments, the air breather will become

blocked after a short period of time.
1 Open the cover of air breather,
2 Replace the element of air breather with new one.
3 Reinstall the cover.
S83490
150 Hydraulic system
Return filter for hammer circuit, replacing

Replace the element in the return filter every 200 hours (on
the basis of hammer working hours).
1 Stop the engine.

2 Loosen the head cover (A)
3 Remove the components from B to H and check for any dam-
age, replace if damaged.
4 Install a new filter element.
5 Install the disassembled components.
6 Tighten the head cover (A).
Tightening torque for the head cover : 100~120 N m (10.2 kgf

S83428
m ~ 12.24 kgf m) (74 lbf ft ~ 88.8 lbf ft).
A
B
H C
D
E
F
G
I
S83473
A Head cover
B Backup ring
C O-ring
D O-ring
E Valve
F O-ring
G Retaining ring
H Element
I Spring
Swing drive unit 151
Swing drive unit

IMPORTANT! Always clean around the oil level gauge before
you check the oil level. Dirt in the oil damages the swing
drive unit.
It is very important that the oil level is always correct and that it is
checked at working temperature.
– Too little oil may lead to that the swing drive unit does not work
correctly and thus be damaged.
– Too much oil makes the oil foam, which causes the swing
drive unit to overheat.
WARNING!
Immediately after operating the machine, the oil is hot.
Allow the oil to cool.
A
Oil level of swing drive unit, checking
B Check the oil level every 250 hours.
C 1 Pull out oil dipstick (A) and wipe it with a clean cloth.
2 Insert oil dipstick and pull it out again.
3 Check the oil level. If the level is in the center of “D”, the level
F is correct.
4 If the level is low, top up oil through oil filler hole (B) to correct
level.
G
5 If the level is high,
D
E – Place a container under the drain plug (F).
S83455
– Open the under cover (E) and protection cap of drain plug
(F).
– Attach the drain hose (G) and drain the oil to the correct
D level.
– Disconnect the drain hose.
D
– Close the drain plug and under cover.
E For oil specification, see page 165.
Oil of swing drive unit, changing

Change the oil after first 500 hours and then every 1000 hours.
S83456
1 Place the container under the valve on the swing drive unit for
receiving the drained oil.
2 Open the under cover (D) and protection cap of drain plug (F).
3 Attach the drain hose (G) and drain the oil. The hose is the
same hose as that used for engine oil draining.
IMPORTANT! Take care of waste oil/liquids in an environmen-
tally safe way.
4 Disconnect the drain hose.
5 Close the drain plug and under cover.
6 Pull out oil dipstick (A), and fill oil to the correct level through oil
filler hole (B).
7 Check the oil level again and if necessary, top up.
Wait about 5 minutes for checking the level accurately after filling
oil.
For oil specification, see page 165.
152 Swing gear and bath
Swing gear and bath

Swing gear bearing, greasing
Grease the swing gear every 250 hours.
1 Park the machine on level ground.
2 Lower the bucket to the ground.
ly. See page 59.
A 5 Fill the grease in the grease nipples (A) at three points using a
A
hand or power grease gun.
S83430
6 Start the engine. Raise the bucket several inches off the ground
A and rotate the superstructure 40 ° (1/9 turn).
8 Repeat the procedure three times, beginning with step 3.
9 Apply grease to the swing bearing until grease can be seen
from the swing bearing seals.
10 Take care not to supply excessive mount of grease.
11 After greasing, clean off the superfluous grease completely.
Grease of swing bath, checking

1 Park the machine on a level ground and move the superstruc-
ture as shown in the figure.
ly. See page 59.
B 5 Remove bolts and cover (B).
6 Check the level and condition of the grease.Fill if needed.
S83429
7 Inspect the seal. Replace the seal if damaged.
8 Install the cover.
If the grease is contaminated or discoloured with water, remove

bolt (C) and drain cover (D), and then change the grease.
S83474
D C
Track drive unit 153
Track drive unit

IMPORTANT! Always clean around the check plug before you
check the oil level. Dirt in the oil damages the track drive
unit.
It is very important that the oil level is always correct and that it is
checked at working temperature.
– Too little oil may lead to that the swing drive unit does not work
correctly and thus be damaged.
– Too much oil makes the oil foam, which causes the swing
drive unit to overheat.
WARNING!
Immediately after operating the machine, the oil is hot.
Allow the oil to cool. Residual pressure in the drive unit,
may cause the plug to be dislodged suddenly and oil to jet
out.
Oil level in track drive unit, checking

Check the oil level every 250 hours.
1 Turn the case so that drain plug (A) is at the bottom.
2 Remove the plug (B). If the oil is about to overflow from the
hole, the level is correct.
If the oil is low, top up the oil to the correct level through the plug
B OIL FILL
LEVEL (B).
OIL DRAIN For oil specification, see page 165.
Oil in track drive unit, changing

S83475
A Change the oil after first 500 hours and then every 2000 hours.
1 Turn the case so that drain plug (A) is at the bottom.

2 Place a container under the drain plug (A) for receiving the
drained oil.
3 Remove the drain plug (A) and plug (B), and then drain the oil.
IMPORTANT! Take care of waste oil/liquids in an environmen-
tally safe way.
4 Check the O-ring on the plugs, if damaged, replace it.
5 Install the drain plug (A).
6 Fill the oil to the correct level through hole after removing the
plug (B)
7 Install the plug (B).
For oil specification, see page 165.
154 Accumulator, handling
Accumulator, handling
WARNING!
The accumulator is charged with highly pressured nitrogen
gas. Handle it with care. Otherwise, it cause serious
accidents or injuries.
– Do not hit, drill or weld the accumulator.
– Keep it away from open flame or other highly heated sources.
– If you operate the operating lever downward just after the en-
gine stops, the accumulator allows the attachment to move by
its own weight.
– After releasing the pressure in accumulator, move the control
lock-out lever down to lock the system securely, see page 59.
Operation of accumulator (in emergency)

1 Stop the engine by turning the ignition key to stop position
2 Turn the ignition key to running position
3 Move the control lock-out lever up to unlock the system, see
page 59.
4 Put the operating lever to boom down position to lower the at-
tachment by its own weight.
ly.
Accumulator pressure, releasing

1 Lower the attachment completely to the ground.
2 Keep all the attachments such as hammer closed.
3 After turning off the engine, turn the ignition key to running po-
S83431 sition.
4 Move the control lock-out lever up 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.
ly.
8 To release the pressure completely, loosen the hose connec-
tion slowly when you disconnect the accumulator. Step aside
in this case as oil should jet out.
Ask your authorized Volvo CE dealer workshop to discharge
the pressure in the accumulator prior to disposal.
Track unit 155
Track unit
Track tension, checking
Check the track tension every 100 hours.
WARNING!
When inspecting the track tension, the track must be lifted
off the ground. Be very careful that the machine does not
drop or move while measuring.
NOTE! When two persons are working, the operator should
follow the sign of the maintenance worker.
The degree of wear condition of track link pins 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 significantly
accelerates wear rates of the sprockets, pins / bushings, idlers and
track links as the track load and tension increase. Generally, pack-
ing effects cannot be controlled except by constant cleaning or re-
moval of the material.
Therefore thoroughly clean the undercarriage at least daily or
more often according to soil conditions in job-site.
1 Raise the track by using boom and arm. For this movement, op-
erate the lever slowly.
2 Measure (L), the clearance between the bottom of track frame
S80313
and the upper surface of track shoe.
3 Adjust the track tension according to the soil characteristics.
Recommended track tension is as below,
L
Working condition Clearance (L, mm)
General soil 420 – 440
Rocky ground 400 – 420
Moderate soil like gravel, sand, 440 – 460
snow, etc.
156 Track unit
Track tension, adjusting

IMPORTANT! Valve (A) may suddenly dislodged due to the
high pressure of the compressed grease in the cylinder.
When loosening valve (A), do not loosen it more than one
turn.
IMPORTANT! Do not loosen other parts except valve (A).
Step aside from the trajectory path of the valve. If the tension
can not be adjusted by the way shown in this manual, con-
S82245B
tact an authorized Volvo CE dealer workshop.
Tightening track tension - reducing slack

1 Fill the grease through grease nipple (B) using a grease gun
with high pressure.
2 Check the tension by moving the machine forward and rear-
ward.
A 3 Check the tension again. If not correct, adjust it again.
B
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.
WARNING!
Do not use the nipple (B) to drain the grease, the nipple can
be ejected suddenly by internal high pressure in the
cylinder.
2 Close the valve (A) but do not tighten excessively as the fitting
may be damaged.
3 Check the tension by moving the machine forward and rear-
ward.
4 Check the tension again. If not correct, adjust it again.
Track shoe bolts, checking

Check the shoe bolts daily.
If track shoe bolts (A) are loosed, the track shoes are likely to be
damaged.
1 Check for looseness and tighten the bolts to specified torque,
185 ~ 195 kgf·m (1814~1912 N m / 1336~1408 lbf ft)
2 After tightening, check whether the nut and the shoe are in full
A contact with the mating surfaces of the link.
S80303A
Tighten the bolts in the order as shown in the figure.
1 3
4 2
S80304
Bucket 157
Bucket
Bucket teeth, replacing
Replace the bucket teeth before the adaptors wear away.
WARNING!
Wear a hard hat, protective glasses, gloves and work shoes
when removing the locking pins.
S80293C
1 Lower the bucket horizontally and place it on a block.

2 Stop the engine and move the control lock-out lever down to
lock the system securely.
3 Clean the opening for the adapter’s lock pin.
4 Place the round bar with a smaller diameter than the lock pin in
the opening for the lock pin.
A 5 Drive out the lock pin (B) using a hammer, so that the lock re-
tainer is removed from its seat.
S83491
6 Thoroughly clean the adapter’s nose and the hole for the lock
B pin, so that the tooth and lock pin can be fitted in the correct
position.
7 Fit the tooth on the adapter’s nose, so that the tooth’s guide
lugs fit in the adapter’s slots.
S83492
8 Fit the lock pin in the adapter’s nose, so that the arrow on the
lock pin faces down and the lock retainer faces forward the tip
of the tooth. Always use a new lock retainer in the correct size.
9 Check manually that the lock pin has been mounted correctly.
S83493
10 Drive down the lock pin using a hammer so that the lock pin is
flush with the top of the adapter body.
11 Drive down the lock pin to the correct position with a hammer
and the round bar. Use a correctly sized tool.
S83494
12 The lock pin is mounted correctly when the mark in the hole is
visible just above the lock pin.
S83495
158 Excavator unit, greasing
Excavator unit, greasing

Grease a new machine every 10 hours or daily only during first 100 hours.
After first 100 hours of operation, grease the excavator unit every 50 hours or weekly.
NOTE! Under severe operating conditions where mud, water, and abrasive material may enter the bear-
ings, or after using the hydraulic hammer, the excavator unit should be greased every 10 hours or daily.
NOTE! When greasing the pin at the point of boom and arm connection, secure that the grease is fully fed
up. If the grease fed is not enough, seizing on the pin will be occur.
When greasing by hand, lower the attachment to the ground as illustrated, and stop the engine.
Grease through the grease nipples using a hand or power grease gun.
After greasing, clean off the superfluous grease.
Immediately after working under water, grease the submerged parts such as the bucket pins to remove the old
grease, regardless of the grease interval.
For grease specification, see page 165.
11 10
12 9
8
5 3 4
7 3
6 2
5
1
S83432
1 Boom cylinder mounting pin (2 points) 7 Bucket cylinder mounting pin (1 point)
2 Boom mounting pin (2 points) 8 Pin between of arm and bucket (1 points)
3 Boom cylinder rod end pin (2 points) 9 Pin between of arm and link (1 point)
4 Arm cylinder mounting pin (1 point) 10 Pin between of connecting rod and link (2 points)
5 Pin between boom and arm (2 points) 11 Bucket cylinder rod end pin (1 point)
6 Arm cylinder rod end pin (1 point) 12 Pin between of bucket and connecting rod (2 points)
Excavator unit, greasing 159
Counterweight removal apparatus, greas-

ing (optional equipment)
S84017
S84018
A
2 Electric greasing system (optional equip-
1
ment)
Electric greasing system is equipped as an optional equipment for
B easier greasing operation.
1 Check that grease in the grease can (D) is sufficient.
2 Turn the switch on (2).
3 Hold the grease gun(B) and uncord the hose (C).
4 Grease at the point you want using the grease gun.
C D S83500 5 After finishing the work, turn off the switch (1).
6 Rewind the hose and put the gun on the original location.
A Fuse
B Grease gun
C Grease hose
D Grease can
1 Switch Off
2 Switch On
160 Lubrication
Lubrication
Lubrication is an important part of preventive maintenance.
The service life of bushings, bearings and bearing pins can be
extended considerably if the machine is lubricated in a cor-
rect way. A lubrication chart makes lubrication work easier
and reduces the risk of forgetting greasing points.
Lubrication has two main purposes:

– To supply grease to the bearing in order to reduce wear be-
tween 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 pen-
etrating into the bearing.
IMPORTANT! Wipe off the grease nipples and the grease gun
before greasing, to avoid introducing sand and dirt particles
with the grease.
Symbol key for “Lubrication and service chart"

These standard symbols are used in the Lubrication and service
chart, see the adjacent table.
1 Engine oil
1 2 3 2 Grease lubrication
3 Swing drive gear oil change
S
4 Swing drive gear oil check
4 5 6 5 Track drive gear oil check
6 Track drive gear oil change
S T T
7 Hydraulic oil
7 8 9 8 Hydraulic oil level
9 Hydraulic oil filter
10 Hydraulic oil tank breather filter
11 Fuel filter
10 11 12 12 Water separator
13 Engine, coolant
14 Engine, coolant filter
15 Engine coolant level
13 14 15 16 Engine oil level
17 Engine oil filter
18 Operator manual
19 Air cleaner filter
16 17 18
19
S86592
Lubrication and service chart 161
Lubrication and service chart
4 16 1 21 2
6000h
2000h
1000h 9
500h
250h
100h 14
50h
2
10h
3
15
4
9
6 10
S 11
17 S
12
18
19
2 2 2 2
10h
50h T 7
100h
250h
T 20
500h
1000h
2000h
6000h
4 4 8 4 5 S82384A
162 Lubrication and service chart
Measure Item Page

DAILY (every 10 hours)
Check engine oil level 1 131
Check coolant level 2 141
Check hydraulic oil level 3 147
Check track shoe bolts 156
Every 50 hours
Lubricate to attachments 4 158
Every 100 hours after carrying out Daily and 50 hours services
Check track tension 5 155
Drain the sediment from fuel tank 134
Every 200 hours after carrying out Daily, 50 and 100 hours services)
Change the return filter for hammer circuit 150
Every 250 hours after carrying out Daily, 50, 100 and 200 hours services
Check battery electrolyte level 144
Check oil level of swing drive unit 6 151
Check oil level of track drive unit 7 153
Lubricate the swing gear bearing 8 152
Every 500 hours after carrying out Daily, 50, 100, 200 and 250 hours
services
Check the density of anti-freeze 140
Check the grease of swing bath 152
Change engine oil and oil filter 9 132
Change fuel filter 10 134
Change water separator element 11 135
Change hydraulic drain filter (first change : 250 hours) 12 148
Clean the radiator, oil cooler and condenser fins 140
Lubrication and service chart 163
Measure Item Page

Every 1000 hours after carrying out Daily, 50, 100, 200, 250 and 500
hours services
Change hydraulic oil return filter (First change : 250 hours) 14 148
Change hydraulic pilot filter (First change : 250 hours) 15 149
Change the primary filter of air cleaner 16 137
Change the oil of swing drive unit (First change : 500 hours) 17 151
Every 2000 hours after carrying out Daily, 50, 100, 200, 250, 500 and
1000 hours services
Clean the suction strainer of hydraulic tank 149
Change the secondary filter of aircleaner 138
Change hydraulic oil 18 147
Change the filter of airbreather in hydraulic tank 19 149
Change the filter of airbreather in fuel tank 136
Change the oil of travel drive unit (First change : 500 hours) 20 153
Every 4000 hours after carrying out Daily, 50, 100, 200, 250, 500, 1000
and 2000 hours services
Check valve clearance 132
Every 6000 hours after carrying out Daily, 50, 100, 200, 250, 500, 1000
,2000 and 4000 hours services
Change coolant 21 141
164 Periodic replacement of critical parts for safety
Periodic replacement of critical parts for safety

To ensure safety at all times when operating or driving the machine, the operator of the machine must always
carry out periodic maintenance. To further improve safety, the operator should also carry out periodic replacement
of the parts given in the table.
These parts are closely connected to safety and fire prevention. With these parts, the material changes as time
passes, or they easily wear or deteriorate. However, it is difficult to judge the condition of the parts simply by pe-
riodic maintenance, so they should always be replaced after a fixed time has passed, regardless of their condition.
It is necessary to ensure that they always maintain their function completely.
However, if these parts show any abnormality before the replacement interval has passed, they should be re-
paired or replaced immediately. If the hose clamps show any deterioration, such as deformation or cracking, re-
place 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. Ask your Volvo CE dealer when replacing the critical parts for safety.
Inspection interval Item

Daily Fuel / hydraulic hose - leakage of connections and end fittings
Monthly Fuel / hydraulic hose - leakage, damage of connections and end fittings
Yearly Fuel / hydraulic hose - leakage, damage, deformity and aging of connections and end
fittings
Safety critical parts for periodic replacement Replacement interval
Fuel hose
Engine Heater hose
Turbocharger lubricating oil hose
Pump, inlet hose
Every 2 years or 4000
Body Pump, outlet hose hours, which occurs first
Swing line hose
Hydraulics
Boom cylinder hose
Attachments Arm cylinder line hose
Bucket cylinder line hose
Seat belt Every 3 years
Specifications
Recommended lubricants 165
Specifications
Recommended lubricants
System Oil grade Recommended viscosity at varying
ambient temperature
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
Engine oil SAE5W-30
VDS-3,
SAE 10W-30
API CI-4 + VDS-2,
Engine ACEA-E5 + VDS-2, *SAE 15W-40
ACEA-E7 + VDS-2, SAE 30
EO-N Premium plus +
VDS-2 SAE 40
Track reduction Gear oil (with EP additive) *SAE 90
gearbox API GL4 or GL5 SAE 140
Gear oil (with EP additive) *SAE 90
Swing gearbox
API GL4 or GL5 SAE 140
Swing ring gear
Grease Multi purpose EP-grease NLGI 2
(Bath and Ball)
ISO VG32 HV
Hydraulic oil (Anti-wear
hydraulic oil with high vis- ISO VG46 HV
cosity index 160 or more)
Hydraulic system ISO VG68 HV
Bio oil (based on syn- Bio oil VG32
thetic ester) Bio oil VG46
*ISO-L-XBCFB2
Pin and bushing Grease(NLGI 2 with EP)
(Multi purpose EP-grease NLGI 2)
ASTM
Fuel Diesel fuel D975 No.1
*ASTM D975 No. 2
Cooling system Coolant Volvo genuine coolant (VCS) should be used only.
Air conditioner
Refrigerant HFC R134a
system
°C -30 -20 -10 0 +10 +20 +30 +40 +50
°F -22 -4 +14 +32 +50 +68 +86 +104 +122
* : Installed at factory.
NOTE! When starting the engine in an ambient temperature of lower than 0°C, be sure to use engine oil
of SAE 10W, SAE 10W–30 and SAE 15W–40, even though the ambient temperature goes up to 10°C more
or less in the day time.
NOTE! The fuel should at least meet the legal requirement, and national and international standards for
marketed fuels, for example : EN590 (with nationally adapted temperature requirements), ASTM D975 No
1D and 2D, JIS KK 2204.
NOTE! Sulphure content : According to current legal requirements (the sulphur content should not ex-
ceed 0.3 percent by weight)
NOTE! The content of Volvo Coolant VCS must never be less than 40% of the total mixture.
Specifications
166 Recommended grease
Recommended grease
Product name Region
Manufacturer General region The tropics*
ESSO ESSO EP2 BEACON Q2
CALTEX MULTIFAX EP2 MARFAK ALL PURPOSE 2
GULF GULF CROWN EP2 GULFCROWN EP2 (SPECIAL)
MOBIL MOBILUX EP2 MOBILUX EP2 (SPECIAL)
SHELL ALVANIA EP2 RETINAX HDX-2
TOTAL MULTIS EP2 MULTIS HT2
CASTROL SPHEEROL EPL2 MOLY
* Generally, the ambient temperature is above 40 °C.
Mixability of types of grease with different additives
Mixability of types of grease with additives
Lithium Calcium Aluminium

Lithium Calcium Clay
complex complex complex
Lithium √ √ √
Calcium √ √ √ √
Lithium complex √ √ √ √
Calcium complex √ √
Aluminium complex √ √
Clay √ √ √
√: Acceptable
Specifications
Service capacities and intervals 167
Service capacities and intervals

Change capacities
Oils and other liquids Change capacities
Engine oil 42 litres (11.1 US gal.)

Coolant 65 litres (17.2 US gal.)
Hydraulic tank 350 litres (92.5 US gal.)
Hydraulic system, total 655 litres (173 US gal.)

Swing gearbox (each) 6.0 litres (1.58 US gal.)
Track gearbox (each) 12 litres (3.2 US gal.)
Fuel tank 840 litres (222 US gal.)
Swing ring gear 52 litres (13.7 US gal.)
Intervals between filter replacements

Filter Hours
Engine oil filter 500*
Fuel filter 500
Water separator 500
Air cleaner, primary filter 1000
Air cleaner, secondary filter 2000
Air conditioner / heater filter 2000

Cartridge of drain filter, hydraulic system 500**
Return oil filter, hydraulic system 1000**
Element of pilot filter, hydraulic system 1000**

Breather filter, fuel tank 2000
Breather filter, hydraulic tank 2000
*For conditions which have to be met, see page 132.

** First replacement : 250 hours.
*** First replacement : 500 hours.
Specifications
168 Service capacities and intervals
Intervals between oil and liquid changes

Oil/liquid Hours
Engine oil 500*
Coolant 6000
Hydraulic oil 2000
Swing drive unit oil 1000***
Track drive unit oil 2000***
*For conditions which have to be met, see page 131.

** First replacement : 250 hours.
*** First replacement : 500 hours.
Specifications
Engine, specifications 169
Engine, specifications
Make Volvo D16E
Type 4-stroke, 6-cylinder, straight, water cooled, direct injection, die-

sel, turbocharged, inter cooled
Rated output (Net) 316 kW (424 hp) at 1800 rpm
Maximum torque 2,500 N m (1,845 lb ft) at 1200 rpm
Bore ×Stroke 144 mm × 165 mm
Total displacement 16.1 litres
Compression ratio 18.5 : 1
Low idle (no load) 800 ± 40 rpm

High idle (no load) 1900 ± 40 rpm
Firing order 1-5-3-6-2-4
Lubrication Forced circulation

Oil pressure, low speed (typical) Min. 70 kPa
Oil pressure, rated (typical) 300–600 kPa
Valve clearance Intake 0.3 mm, Exhaust 0.6 mm
Nozzle pressure 33 MPa
Fuel injection pump EUI (Electronic unit injector)
Fuel consumption (rated, full load) 216.4 g/kw·hr

Specifications
170 Electrical system, specifications
Electrical system, specifications

System voltage 24 V
Starter 7.0 kW
Batteries 2 x 12 V
Alternator 28 V / 80 A
Horn sound level at 7 m 100 ±5 dB
Head light type Halogen (70 W)
Fuses
Capacity and symbol related circuits
F1 F6 F10 F15 F20 F24
F2 F7 F11 F16 F21 F25
F3 F12 F17 F26
F4 F8 F13 F18 F22 F27
F5 F9 F14 F19 F23 F28
S82376A
No. Capacity Appliance / circuit No. Capacity Appliance / circuit

IECU (Instrument electronic
F1 10A control unit) F15 - Spare
F2 10A Working lights (deck) F16 15A Start switch
F3 20A Working lights (boom) F17 5A Boom light
F4 10A Wiper & washer F18 10A Radio and cassette
F5 10A Travel alarm F19 20A Auxiliary heater
F6 10A Cigarette lighter F20 10A Power outlet
F7 10A Horn F21 20A Fuel filler pump
F8 20A Air conditioner F22 10A Auto greasing

Extra working lights E-ECU(engine electronic con-
F9 25A (rear, counterweight) F23 20A trol unit)
F10 25A Working lights (cab) F24 5A Engine RPM manual control
V-ECU (vehicle electronic
F11 10A Rotating warning beacon F25 10A control unit)
Seat heater &
F12 15A Safety solenoid F26 10A Air suspension seat
V-ECU (vehicle electronic con-
F13 10A trol unit) F27 20A Hammer, Booster, Shear
F14 5A Overload F28 - Spare

Specifications
Cab, specifications 171
Cab, specifications
Operator seat
This machine is equipped with an operator seat, which meets the criteria of EN ISO 7096.
Vibration and sound information
Hand-arm vibrations
Emission of Hand-Arm Vibration during real operating conditions at its intended use is less than 2.5 m/s2 RMS
(root mean square) acceleration according to ISO 8041.
Whole-body vibrations
Emission of Whole-Body Vibration during real operating conditions at its intended use is less than 0.5 m/s2 RMS
(root mean square) acceleration, according to ISO 8041 for excavating.
Emission of Whole-Body Vibration during real operating conditions at its intended use is according to the table
below.
Typical operation conditions Vibration emission Vibration emission Vibration emis-

value aw,eqx value aw,eqy sion value aw,eqz
(m/s2 RMS) (m/s2 RMS) (m/s2 RMS)
Excavating 0,3 0,2 0,3
Hydraulic break application 0,3 0,2 0,6
Mining application 0,5 0,3 0,6
Transfer movement 0,3 0,2 0,8
The following vibration directions are defined:

X = fore and aft
Y = lateral
Z = vertical
The whole-body vibration values given above have been taken from ISO/CEN Technical Report XXXXXXX (under
development).
NOTE! These whole-body vibration emission values were determined at particular operating and terrain
conditions and are therefore not representative for all the various conditions in accordance with the in-
tended use of the machine and should not alone be used to determine the whole-body vibration exposure
to the operator using the machine. For this purpose the information in ISO/CEN Technical Report
XXXXXXX is recommended.
To ensure that the whole-body vibration emission during machine use is kept to a minimum, see page 92.
Sound information
Sound pressure level (LpA) at operator position 74 LpA dB(A)
(Measurement according to ISO 6396)
Sound power level (LwA) around the machine 108 LwA dB(A)
(Measurement according to 2000/14/EC with
applicable appendices and measuring method
according to ISO 6395)
Specifications
172 Hydraulic system, specifications
Hydraulic system, specifications

Main pump
Model K3V280DTH
Displacement 2 x 242cc/rev
Type Variable swash plate, axial piston pump
Pilot pump
Displacement 15.2 + 20. 3cc/rev

Type Fixed gear
Main control valve
Model UZ36
Main relief pressure 31.4 / 34.3 MPa
(STD / Boost pressure) (320 / 350 kgf/cm2, 4550 / 4980 psi)
Port relief pressure 365 kgf/cm2 (5190 psi) : (Boom/ Arm/ Bucket)
150 / 365 kgf/cm2 : (Option STD / High)
Control pedals
Model RCVD8C
Stroke 12.4 degree
Operating force 108 kgf·cm (94 lbf·in)
Control levers
Model PV48K
Stroke Forward and backward: 25 degree

Right and left: 19 degree
Operating force Forward and backward: 29 kgf·cm
Right and left: 25 kgf·cm
Specifications
Hydraulic system, specifications 173
Track motor
Model MSF - 340VP
Type Fixed swash plate(two speed : low and high), piston motor
Rated pressure 350 kgf/cm2 (4977 psi)
Brake type Wet disc, spring applied, hydraulic released
Gear box, track motor
Type 3-stage planetary

Swing motor
Model SG20E
Type Fixed swash plate, piston motor
Rated pressure 260 kgf/cm2 (3697 psi)
Gear box, swing motor
Type 2-stage planetary

Specifications
174 Total machine, dimensions
Total machine, dimensions

A
D
M
E C
F
K
G I
H J
L B
S83496
6.6 m Boom 7.7 m Boom

Description 21' 8" 25' 3"
Unit
2.9 m Arm 2.9 m Arm 3.55 m Arm 4.2 m Arm
9' 6" 9' 6" 11' 8" 13' 9"
A. Overall width of superstructure mm 3420 3420 3420 3420
ft-in 11' 3" 11' 3" 11' 3" 11' 3"
mm 4286 4286 4286 4286
B. Overall width ft-in 14' 1" 14' 1" 14' 1" 14' 1"
3510 3510 3510 3510
C. Overall height of cab 11' 6" 11' 6" 11' 6" 11' 6"
D. Tail swing radius 4090 4090 4090 4090
13' 5" 13' 5" 13' 5" 13' 5"
3590 3590 3590 3590
E. Overall height of raicap 11' 10" 11' 10" 11' 10" 11' 10"
mm 1507 1507 1507 1507
F. *Counterweight clearance ft-in 4' 11" 4' 11" 4' 11" 4' 11"
G. Tumbler length 4750 4750 4750 4750
15' 7" 15' 7" 15' 7" 15' 7"
5990 5990 5990 5990
H. Track length 19' 8" 19' 8" 19' 8" 19' 8"
3350 / 2750 3350 / 2750 3350 / 2750 3350 / 2750
I. Track gauge(Extended/retracted) 11' / 9' 11' / 9' 11' / 9' 11' / 9'
J. Shoe width mm 650 650 650 650
ft-in 2' 2" 2' 2" 2' 2" 2' 2"
858 858 858 858
K. *Min. ground clearance 2' 10" 2' 10" 2' 10" 2' 10"
L. Overall length mm 12200 13320 13220 13170
ft-in 40' 43' 8" 43' 5" 43' 2"
M. Overall height of boom 4855 4660 4600 4950
15' 11" 15' 15' 1" 16' 2"
∗ With shoe grouser
Ground pressure
Description Shoe Boom Arm Bucket Counter- Operating Ground
width m m (kg/lb) weight weight pressure
(mm/in) ft in ft in (kg/lb) (kg/lb) (kPa/psi)
Double 650/26 68,800/151,670 100.1/14.5
grouser 6.6 2.9
750/30 3,730/8220 11,300/24920 69,500/153,220 87.6/12.7
21' 8" 9' 6"
900/36 70,600/155,640 74.2/10.8
650/26 68,300/150,570 99.3/14.4
7.7 3.55
750/30 2,800/6170 11,300/24920 69,000/152,120 87.0/12.6
25' 3" 11' 8"
900/36 70,000/154,320 73.5/10.7
Specifications
Bucket & Arm combination 175
Bucket & Arm combination

Maximum permitted buckets for direct fit
Boom Boom
6.6 m 7.7 m
650 mm shoe, 21' 8" 25' 3"
Unit
11300 kg counterweight
Arm Arm Arm Arm
2.9 m 2.9 m 3.55 m 4.2 m
9' 6" 9' 6" 11' 8" 13' 9"
5200 4175 3875 3500
1.5 t/m3 2530 lb/yd3
6.80 5.46 5.07 4.58
GP bucket
4600 3700 3425 3100
1.8 t/m3 3030lb/yd3
l 6.02 4.84 4.48 4.05
yd3
3
1.8 t/m 3030 lb/yd3 4350 3500 3250 2925
5.69 4.58 4.25 3.83
HD bucket
2.0 t/m3 3370 lb/yd3 4075 3275 3025 2725
5.33 4.28 3.96 3.56
1. Bucket size base on ISO 7451, heaped material with a 1:1 angle of repose.
2. “Maximum permitted sizes” are for reference only.
Boom & Arm, dimension and weight
Boom
A
S86575
6.6 m, 7.7 m,
Description Unit 21' 8" 25' 3"
6890 8020
Length (A) 22' 7" 26' 4"
mm 2530 1970
Height (B) ft in 8' 4" 6' 6"
1100 1100
Width 3' 7" 3' 7"
kg 6550 6900
Weight * lb 14440 15210
* Includes cylinder, piping and pin

Specifications
176 Bucket & Arm combination
Arm
A
S86576
Description Unit 2.9 m 3.55 m HD 4.2 m

9' 6" 11' 8" 13' 9"
Length (A) 4260 4940 5590

14' 0" 16' 2" 18' 4"
mm
Height (B) ft in 1530 1390 1390
5' 0" 4' 11" 4' 11"
740 740 740

Width 2' 5" 2' 5" 2' 5"
kg 3510 3670 3900

Weight * lb 7738 8091 8598
* Includes cylinder, linkage and pin

Specifications
Disassembled parts, dimension and weight 177
Disassembled parts, dimension and weight

Counterweight, dimension and weight
A C
S86578
Length (A) Height (B) Width (C) Weight

mm / ft-in mm / ft-in mm / ft-in kg / lb
3420 1280 800 11400

11' 3" 4' 3" 2' 7" 25132
Lower structure, dimension and weight
A S83477
Shoe width
Description
650 mm 750 mm 900 mm
Length (A) 5990 5990 5990

19' 8" 19' 8" 19' 8"
mm
Width ft in 700 800 950
2' 3.6" 2' 7.5" 3' 1.4"
Height (B) 1375 1375 1375

4' 6" 4' 6" 4' 6"
Weight kg 10400 10750 11250

lb 22927 23700 24802
Specifications
178 Disassembled parts, dimension and weight
Upper structure with lower frame, dimension and weight
A S83478
Description Upper structure with lower frame
5500
Length (A) 18' 0.5"
mm 2735
Height (B) ft in 8' 11.7"
3430
Width 11' 3"
kg 21700
Weight lb 47840
Other disassembled parts, weight
E F
G H
D
I S83479
C
A
A B C D E F G H I
Items
handrail handrail step handrail walkway
34.5 13.5 7.5 18.0 20.0 13.0 14.0 15.0 12.5

Weight (kg / lb) 76 29.8 16.5 39.7 44 28.7 31 33 27.6
Specifications
Digging forces with direct fit bucket 179
Digging forces with direct fit bucket

21' 8" 25' 3"
Description Unit
9' 6" 9' 6" 11' 8" 13' 9"
Bucket radius mm 2215 2150 2150 2150

ft in 7' 3" 7' 1" 7' 1 7' 1
kN 342 326 326 326
Breakout force Normal, kg 34830 33190 33190 33190
ISO lb 76786 73170 73170 73170
kN 374 356 356 356
Power boost, kg 38090 36300 36300 36300
ISO lb 83973 80026 80026 80026
Normal, kN 298 303 265 236

Tearout force ISO kg 30410 30910 27020 24080
lb 67041 68144 59568 53086
kN 326 332 290 258
Power boost, kg 33260 33810 29550 26340
ISO lb 73325 74537 65146 58069
Specifications
180 Working ranges
Working ranges
With direct fit bucket (standard)
A
B
G
D
E
S82248
F
C H

21' 8" 25' 3"
Description Unit
9' 6" 9' 6" 11' 8" 13' 9"
11500 12600 13170 13780

A. Maximum digging reach 37' 9" 41' 3" 43' 3" 45' 2"
11200 12335 12910 13540

B. Maximum digging reach on ground 36' 9" 40' 6" 42' 4" 44' 5"
C. Maximum digging depth 7250 7755 8400 9035

23' 9" 25' 4" 27' 7" 29' 8"
mm 10980 12490 12620 12940

D. Maximum cutting height ft in 36' 0" 41' 41' 5" 42' 6"
6960 8410 8610 8930

E. Maximum dumping height 22' 9" 27' 7" 28' 2" 29' 4"
F. Maximum vertical wall digging depth 5065 6780 7250 7855

16' 7" 22' 2" 23' 11" 28' 3"
5160 5480 5410 5160

G. Minimum front swing radius 16' 11" 18' 0" 17' 10" 16' 11"
Specifications
Lifting capacity 181
Lifting capacity
Unit : lbs
Lifting point from swing center of machine

Distance from
Specifications ground 5 ft 10 ft 15 ft 20 ft 25 ft 30 ft 35 ft Maximum reach
A - - - - - - - * 33640 21.38 ft
30 ft
B - - - - - - - * 33640
A - - - - * 36050 - - * 31010 25.50 ft
25 ft
B - - - - * 36050 - - * 31010
A - - - * 42730 * 38010 - - * 30160 28.14 ft
20 ft
B - - - * 42730 * 38010 - - * 30160
A - - * 62210 * 47580 * 40280 - - * 30460 29.72 ft
15 ft
B - - * 62210 * 47580 38100 - - 28840
Boom : 21 ft 8in A - - *73420 * 53020 *42970 * 37120 - * 31700 30.40 ft

10 ft
B - - * 73420 51260 36700 27820 - 27240
Arm : 9 ft 6 in
A - - * 75640 * 56730 * 44970 * 37460 - * 34170 30.25 ft
Cwt : 24912 lbs 5 ft
B - - * 75640 49140 35500 27280 - 26960
Shoe : 26 in A - - * 76930 * 57540 * 45230 - - * 37500 29.24 ft
0 ft
B - - 75650 47990 34760 - - 27990
A - * 65970 * 71630 * 54970 * 42880 - - * 37580 27.29 ft
-5 ft
B - * 65970 * 71630 47720 34630 - - 30830
A - * 78280 * 61800 * 47880 - - - * 36660 24.16 ft
-10 ft
B - * 78280 * 61800 * 47880 - - - * 36660
A - - * 44030 - - - - * 32320 19.28 ft
-15 ft
B - - * 44030 - - - - * 32320
A - - - - - - - -
-20 ft
B - - - - - - - -
A Along the undercarriage

H/TANK
B H/TANK
Across the undercarriage
1. Machine in “Fine Mode-F” (Power Boost), for lifting capacities.

2. The above loads are in compliance with SAE and ISO Hydraulic Excavator Lift Capacity Standards.
3. Rated loads do not exceed 87% of hydraulic lifting capacity or 75% of tipping load.
4. Rated loads marked with an asterisk ( * ) are limited by hydraulic capacity rather than tipping load.
Specifications
182 Lifting capacity
Unit : lbs

Distance from
A - - - - - - - * 29220 24.40 ft
35 ft
B - - - - - - - * 29220
A - - - - - - - * 26640 28.96 ft
30 ft
B - - - - - - - * 26640
A - - - * 32770 * 30630 - - * 25500 32.10 ft
25 ft
B - - - * 32770 29570 - - * 25500
A - - - * 35050 * 31460 - - * 25150 34.24 ft
20 ft
B - - - * 35050 28990 - - 23050
A - - * 46690 * 38070 * 32970 * 29750 - * 25420 35.55 ft
15 ft
B - - * 46690 37220 28080 21850 - 21260
Boom : 25 ft 3in
A - - * 52030 * 41040 * 34560 * 30260 - * 26290 36.12 ft
Arm : 11ft 3in 10 ft
B - - 49140 35480 27100 21390 - 20330
Cwt : 24912 lbs A - - * 55210 * 43170 * 35720 29990 - * 27840 35.99 ft
5 ft
Shoe : 26 in B - - 46900 34080 26250 20960 - 20110
A - - * 55670 * 43860 * 35950 * 29680 - * 29470 35.15 ft
0 ft
B - - 45760 33170 25670 20720 - 20610
A - * 62170 * 53590 * 42740 * 34680 - - * 29270 33.54 ft
-5 ft
B - * 62170 45450 32800 25460 - - 21980
A * 58150 * 60930 * 48950 * 39280 * 30740 - - * 28580 31.06 ft
-10 ft
B * 58150 * 60930 45770 32960 25750 - - 24680
A * 58980 * 50090 * 40890 * 31980 - - - * 26680 27.44 ft
-15 ft
B * 58980 * 50090 * 40890 * 31980 - - - * 26680
A - - * 26180 - - - - * 21420 22.16 ft
-20 ft
B - - * 26180 - - - - * 21420

H/TANK
B H/TANK

Specifications
Unit : lbs

Distance from
A * 23270 27.31 ft
35 ft
B * 23270
A *27500 * 21440 31.45 ft
30 ft
B *27500 * 21440
A *28160 * 20560 34.37 ft
25 ft
B *28160 * 20560
A *32440 *29300 *27350 * 20290 36.37 ft
20 ft
B *32440 29090 22230 * 20290
A *57600 *43170 *35620 *31020 *28030 * 20470 37.60 ft
15 ft
B *57600 *43170 *35620 28050 21740 19130
Boom : 25 ft 3in
A *48990 *38900 *32880 *28890 * 21090 38.14 ft
Arm : 13ft 9in 10 ft
B *48990 35500 26930 21120 18310
Cwt : 24912 lbs A *53120 *41510 *34390 *29540 * 22230 38.02 ft
5 ft
Shoe : 26 in B 46830 33840 25920 20550 18080
A *44100 *54740 *42850 *35130 29160 * 24000 37.23 ft
0 ft
B *44100 45210 32680 25160 20140 18440
A *32080 *59540 *53820 *42530 *34630 *28130 * 26790 35.71 ft
-5 ft
B *32080 *59540 44530 32080 24760 20020 19510
A *39830 *51510 *64540 *50410 *40170 *32210 * 26690 33.39 ft
-10 ft
B *39830 *51510 *64540 44590 32020 24800 21590
A *69790 *55200 *43990 *34880 *25690 * 25540 30.06 ft
-15 ft
B *69790 *55200 *43990 32540 25530 25460
A *40980 *32810 *23290 * 22420 25.34 ft
-20 ft
B *40980 *32810 *23290 * 22420

H/TANK
B H/TANK

Specifications
Unit : kg

Distance from
Specifications ground 1.5 m 3m 4.5 m 6m 7.5 m 9m 10.5m Maximum reach
A - - - - - - - * 15090 6661 mm
9m
B - - - - - - - * 15090
A - - - - * 16990 - - * 14020 7848 mm
7.5 m
B - - - - * 16990 - - * 14020
A - - - * 19520 * 17400 - - * 13670 8617 mm
6m
B - - - * 19520 * 17400 - - * 13670
A - - * 28970 * 21990 * 18530 * 15500 - * 13820 9075 mm
4.5 m
B - - * 28970 * 21990 17680 13210 - 13030
A - - - * 24520 * 19800 * 17050 - * 14410 9269 mm
Boom : 6.6m 3m
B - - - 23770 17020 12920 - 12340
Arm : 2.9 m
A - - * 31650 * 26190 * 20730 * 17280 - * 15500 9217 mm
Cwt : 11300 kg -1.5 m
B - - * 31650 22810 16470 12650 - 12230
Shoe : 650 mm A - - * 35410 * 26540 * 20910 - - * 17010 8912 mm
0m
B - - 35260 22290 16120 - - 12690
A - * 29150 * 32960 * 25370 * 19870 - - * 17050 8329 mm
-1.5 m
B - * 29150 * 32960 22160 16050 - - 13950
A - * 36010 * 28540 * 22230 - - - * 16650 7400 mm
-3 m
B - * 36010 * 28540 * 22230 - - - * 16650
A - - * 20730 - - - - * 14830 5964 mm
-4.5 m
B - - * 20730 - - - - * 14830
A - - - - - - - -
--6 m
B - - - - - - - -

H/TANK
B H/TANK

Specifications
Unit : kg

Distance from
A - - - - * 15030 * 13970 - * 11530 9847 mm

7.5 m
B - - - - * 15030 13780 - * 11530
A - - - * 18940 * 16140 * 14430 - * 11390 10469 mm
6m
B - - - * 18940 * 16140 13470 - 10390
A - - - * 21640 * 17570 * 15160 * 13630 * 11540 10848 mm
4.5 m
B - - - * 21640 17250 13030 10170 9610
A - - - * 24090 * 18950 * 15920 * 13920 * 11940 11011 mm
3m
Boom : 7.7 m B - - - 22770 16450 12570 9940 9210
A - - - * 25510 * 19930 * 16470 * 13920 * 12630 10967 mm
Arm : 3.55 m -1.5 m
B - - - 21760 15800 12180 9730 9120
Cwt : 11300 kg
A - - - * 25670 * 20240 * 16590 * 13790 * 13360 10713 mm
Shoe : 650 mm 0m
B - - - 21250 15390 11900 9600 9340
A - - * 27060 * 24700 * 19730 * 16060 - * 13280 10233 mm
-1.5 m
B - - * 27060 21120 15220 11800 - 9950
A - * 25700 * 28040 * 22600 * 18200 * 14410 - * 12980 9494 mm
-3 m
B - * 25700 * 28040 21260 15280 11910 - 11140
A - * 27250 * 23200 * 19020 * 15050 - - * 12160 8426 mm
-4.5 m
B - * 27250 * 23200 * 19020 * 15050 - - * 12160
A - - * 15770 * 12710 - - - * 9960 6877 mm
--6 m
B - - * 15770 * 12710 - - - * 9960

H/TANK
B H/TANK

Specifications
Unit : kg

Distance from
A - - - - - * 10430 8487 mm
10.5 m
B - - - - - * 10430
A - - - - - *12760 - * 9670 9683 mm
9m
B - - - - - *12760 - * 9670
A - - - - *12860 *9640 * 9310 10532 mm
7.5 m
B - - - - *12860 *9640 * 9310
A *14940 *13440 *12490 * 9200 11115 mm
6m
B *14940 *13440 10370 * 9200
A *20010 *16440 *14270 *12850 * 9300 11473 mm
4.5 m
B *20010 *16440 13020 10110 8650
Boom : 7.7 m
A *22690 *17960 *15150 *13290 * 9570 11628 mm
Arm : 4.2 m 3m
B *22690 16460 12500 9820 8290
Cwt : 11300 kg A *24560 *19160 *15860 *13610 * 10090 11586 mm
-1.5 m
Shoe : 650 mm B 21730 15700 12030 9540 8200
A *19060 *25260 *19770 *16210 13540 * 10880 11346 mm
0m
B *19060 20990 15160 11680 9340 8360
A *14180 *25980 *24820 *19630 *16010 *13110 * 12130 10894 mm
-1.5 m
B *14180 *25980 20690 14890 11490 9270 8830
A *17770 *22800 *29740 *23270 *18590 *14980 * 12120 10203 mm
-3 m
B *17770 *22800 *29740 20720 14850 11490 9750
A *32260 *25560 *20410 *16280 *12350 * 11620 9219 mm
-4.5 m
B *32260 *25560 *20410 15080 11770 11440
A *19270 *15540 *11480 *10310 7829 mm
--6 m
B *19270 *15540 *11480 *10310

H/TANK
B H/TANK

Specifications
Unit : kg

Distance from
A *17020 6774 mm
10.5 m
B *17020
A *15700 * 15470 8225 mm
9m
B *15700 * 15470
A *15990 *14880 * 14690 9211 mm
7.5 m
B *15990 13420 12850
A *20200 *16980 *15100 * 14420 9873
6m
B *20200 *16980 13200 11260
A *22770 *18270 *15680 * 14300 10275 mm
4.5 m
B *22770 16880 12800 10350
Boom : 7.7 m
A *24870 *19450 *16270 14130 10447 mm
Arm : 2.9 m 3m
B 22190 16130 12390 9900
Cwt : 11300 kg A *25700 *20140 *16610 14070 10400 mm
-1.5 m
Shoe : 650 mm B 21400 15570 12050 9810
A *25260 *20110 *1646 * 14050 10132 mm
0m
B 21090 15260 11850 10110
A *26450 *23760 *19200 *15480 * 13800 9623 mm
-1.5 m
B *26450 21110 15200 11840 10890
A *26630 *25220 *21120 *17090 * 13210 8833 mm
-3 m
B *26630 *25220 *21120 15380 12420
A *19810 *16720 *12510 * 11770 7672 mm
-4.5 m
B *19810 *16720 *12510 * 11770
A
--6 m
B

H/TANK
B H/TANK

Specifications
188 Service history
Service history
Service 100 hours Type of service Signature and stamp
Date Hours ! Warranty inspection
Date Hours ! Service and maintenance
Date Hours ! Warranty inspection

! Service and maintenance

Specifications
Service history 189

Specifications
190 Service history

Specifications
Service history 191

Specifications
Alphabetical index
193
Alphabetical index Engine block heater (optional equipment) ..................... 77

Engine oil filter, replacing............................................. 132
Accumulator pressure, releasing..................................154 Engine oil level, checking ............................................ 131
Accumulator, handling .................................................154 Engine oil, changing ................................................... 131
Adjustable track gauge ................................................107 Engine....................................................................... 5,131
Air breather filter on hydraulic tank, replacing..............149 Engine, specifications .................................................. 169
Air cleaner ....................................................................137 Entering / leaving / climbing the machine .................... 118
Air conditioner / heater (optional equipment)............35,67 Escaping from swampy ground ..................................... 95
Air conditioner filter, cleaning .......................................146 Excavator unit, greasing .............................................. 158
Air conditioner ..............................................................146 Fan belt tension, checking........................................... 142
Air ventilation filter on fuel tank, changing ...................136 Fire extinguisher (optional equipment) .......................... 65
Alphabetical index ........................................................193 Fire prevention............................................................. 121
Alternator and compressor belt tension, checking .......145 FOPS and FOG ............................................................... 6
Anti-vandalism (optional equipment)..............................67 Foreword.......................................................................... 1
Arrival and Delivery Inspections...................................127 Front instrument panel (IECU)....................................... 24
Ashtray ...........................................................................65 Front window, closing .................................................... 62
Assembling after transportation .....................................85 Front window, opening................................................... 62
Attachment lowering after hose rupture .......................100 Fuel main filter, changing............................................. 134
Backhoe work ................................................................97 Fuel system ................................................................. 133
Batteries, rules .............................................................144 Fuel system, air bleeding............................................. 135
Battery disconnect switch ............................................143 Fuel tank, draining ....................................................... 134
Battery electrolyte level, checking................................144 Fuel, filling.................................................................... 133
Battery, charging ..........................................................145 Fuse box...................................................................... 144
Before service, read .....................................................119 Fuses........................................................................... 170
Boom & Arm, dimension and weight ............................175 Glove compartment ....................................................... 64
Boom cylinder and boom with dipper arm cylinder, Grease of swing bath, checking................................... 152
disassembling ................................................................82 Ground pressure.......................................................... 174
Boom float position (optional equipment).....................101 Handling hazardous materials ..................................... 123
Bucket & Arm combination...........................................175 High voltage overhead power line ................................. 72
Bucket teeth, replacing ................................................157 Hose rupture valves (optional equipment) ................... 100
Bucket ..........................................................................157 Hydraulic drain filter, replacing .................................... 148
Bucket, changing ...........................................................98 Hydraulic hammer (optional equipment)...................... 110
Cab ..................................................................................6 Hydraulic oil level, checking......................................... 147
Cab, specifications .......................................................171 Hydraulic oil return filter, replacing .............................. 148
CE marking, EMC directive ..............................................9 Hydraulic oil, changing................................................. 147
Change capacities .......................................................167 Hydraulic pump................................................................ 7
Checking instruments, warning and control lamps.........75 Hydraulic system ......................................................... 147
Cleaning engine compartment .....................................129 Hydraulic system, specifications.................................. 172
Cleaning the machine ..................................................128 Identification numbers...................................................... 2
Coat hook.......................................................................64 Ignition key..................................................................... 37
Communication equipment, installation .........................10 Information and warning decals..................................... 12
Control lock-out system .................................................59 Instrument panels .......................................................... 23
Coolant level, checking ................................................141 Intended use.................................................................... 5
Coolant properties, checking .......................................140 Intercooler.................................................................... 136
Coolant, changing ........................................................141 Intervals between filter replacements .......................... 167
Cooling system ............................................................140 Intervals between oil and liquid changes..................... 168
Counterweight removal apparatus, greasing Left instrument panel ..................................................... 44
(optional equipment) ....................................................159 Levers and pedals ......................................................... 53
Counterweight ..............................................................102 Lifting capacity ............................................................. 181
Counterweight, dimension and weight .........................177 Lifting objects............................................................... 109
Counterweight, disassembling .......................................82 Lifting the machine......................................................... 87
Counterweight, installation (for standard machine)......102 Loading and securing the machine................................ 86
Counterweight, installation Loading on to a vehicle.................................................. 91
(with optional removing device)....................................105 Loading work ................................................................. 97
Counterweight, removal (for standard machine ...........102 Long-term parking.......................................................... 79
Counterweight, removal Lower structure, dimension and weight ....................... 177
(with optional removing device)....................................103 Lower window, removing ............................................... 62
Cup and drink holder......................................................64 Lubrication and service chart................................ 127,161
Delivery Instructions.....................................................127 Lubrication ................................................................... 160
Digging forces with direct fit bucket..............................179 Machine view ................................................................... 8
Dipper arm with bucket cylinder, disassembling ............81 Main control valve............................................................ 7
Disassembled parts for transportation ...........................80 Manual release of negative brake.................................. 88
Disassembled parts, dimension and weight.................177 Maximum permitted buckets for direct fit ..................... 175
Ditching work .................................................................97 Measures before operating............................................ 74
Door lock ........................................................................63 Mirrors, handrail, step and walkway, disassembling...... 84
Dry type precleaner (optional equipment) ....................138 Modifications.................................................................... 7
Dry-type precleaner, disassembling...............................85 Oil in track drive unit, changing.................................... 153
Electric greasing system (optional equipment) ............159 Oil level in track drive unit, checking............................ 153
Electric welding ............................................................146 Oil level of swing drive unit, checking .......................... 151
Electrical system .......................................................5,143 Oil of swing drive unit, changing .................................. 151
Electrical system, specifications...................................170 Operating (working) on public roads.............................. 73
Emergency exit ..............................................................66 Operating instructions.................................................... 69
Alphabetical index
194
Operating techniques .....................................................89 Track gauge, extending ............................................... 107

Operating under ground .................................................73 Track gauge, retracting................................................ 107
Operation of accumulator (in emergency)....................154 Track motor and gearbox................................................. 6
Operator comfort ............................................................60 Track shoe bolts, checking .......................................... 156
Operator obligations.......................................................70 Track tension, adjusting............................................... 156
Operator seat .................................................................60 Track tension, checking ............................................... 155
Operator’s safety............................................................71 Track unit ..................................................................... 155
Optional parts.................................................................57 Transporting the machine.............................................. 80
Other controls ................................................................53 Travelling on uneven ground ......................................... 95
Other disassembled parts, weight................................178 Turbocharger ............................................................... 136
Overhead railway power lines ........................................73 Under carriage, disassembling ...................................... 83
Paint finish maintenance ..............................................128 Underground cables and pipes...................................... 72
Parking ...........................................................................78 Upper instrument panel ................................................. 38
Periodic replacement of critical parts for safety ...........164 Upper structure with lower frame,
Permissible depth of water.............................................95 dimension and weight .................................................. 178
Pilot filter, replacing......................................................149 Valve clearance, adjusting........................................... 132
Presentation .....................................................................5 Vibration and sound information .................................. 171
Primary filter, cleaning and changing ...........................137 Water separator element, changing............................. 135
Product plates ................................................................11 Water separator, draining ............................................ 135
Protection from falling or scattering materials When working, do not:................................................... 91
(optional equipment) ......................................................66 Whole-body vibrations ................................................... 92
Radiator, oil cooler and condenser fins, cleaning ........140 Window fixer .................................................................. 65
Radio and cassette player .............................................67 With direct fit bucket (standard) ................................... 180
Rear instrument panel....................................................49 Working in cold weather ................................................ 96
Recommended grease.................................................166 Working in confined spaces........................................... 73
Recommended lubricants ............................................165 Working in low light conditions....................................... 73
Relays and slow blow fuse...........................................143 Working in other dangerous areas................................. 73
Return filter for hammer circuit, replacing Working on slopes ......................................................... 94
(optional equipment) ....................................................150 Working ranges............................................................ 180
Right instrument panel ...................................................35 Working with bucket....................................................... 97
Roof window and rain shield ..........................................63 Working with long range attachment ............................. 99
Rotating beacon lamp, disassembling Working within dangerous area ..................................... 72
(optional equipment) ......................................................85
Rules for digging ............................................................90
Running-in instructions ..................................................69
Safety regulations ............................................................1
Safety rules when operating ..........................................70
Safety when servicing ..................................................117
Seat belt .........................................................................61
Secondary filter, changing ...........................................138
Selecting track shoes ...................................................108
Service and maintenance ............................................127
Service capacities and intervals...................................167
Service history ......................................................127,188
Service points ..............................................................130
Service position A ........................................................117
Service position B ........................................................117
Service position............................................................117
Service Programmes ...................................................127
Signalling diagram .......................................................113
Specifications ...............................................................165
Starting with booster batteries .......................................77
Starting...........................................................................76
Stopping and parking .....................................................78
Stopping .........................................................................78
Storage for the Operator’s manual.................................65
Strainer, cleaning and changing ..................................149
Sun shade ......................................................................64
Sunlight protection roof ..................................................63
Swing drive unit............................................................151
Swing gear and bath ....................................................152
Swing gear bearing, greasing ......................................152
Swing motor and gearbox ................................................6
Table of contents .............................................................3
The USA federal clean air act ........................................19
Total and disassembled specifications,
weight and dimension ....................................................80
Total machine, dimensions .........................................174
Touching up paint finish ...............................................128
Towing the machine .......................................................88
Track drive unit ............................................................153
Track gauge, adjustment ...............................................80
Alphabetical index
195
Ref.No. 21A1001541 English
Printed in Korea CST
Volvo, Pyongtaek

Excavator Operator Manual

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Excavator Operator Manual

Hochgeladen von

Copyright:

Verfügbare Formate

EC700B OPERATOR'S MANUAL

Many hours are spent on design and production to make a

Service and maintenance

Volvo Construction Equipment Korea Ltd.

Please send any comments regarding the Operator's Manual to om@volvo.com

Safety when servicing ..........................................117

Track motor and gearbox

Swing motor and gearbox

Anti-theft device (optional equipment)

FOPS and FOG

Main control valve

1 Dipper arm cylinder 13 Radiator and Charged air cooler

CE marking, EMC directive

Protection against electromagnetic interference

Information and warning decals

3 WARNING! Safety locking 4 WARNING! Do not step or walk

5 WARNING! Rotating parts 6 WARNING! Hot and pressurized coolant

CHECK THE EXISTING CONTROL PATTERN TYPE BEFORE MOVING ANY

7 WARNING! Pattern change (optional) 8 WARNING! Boom float position

9 WARNING! Operating the optional attachment 10 WARNING! High voltage

11 WARNING! Do not smoke when fueling 12 WARNING! Removal counterweight device

13 WARNING! Handling accumulator 14 WARNING! Risk of fire when fueling

15 WARNING! Excavator’s working area 16 WARNING! Risk of slipping or falling

17 WARNING! Battery 18 WARNING! Rotating and / or hot parts

25 Lifting point 26 Auto / Manual switches. See page 47.

27 Coolant information 28 Machine specifications (Optional)

X(m) > 3.0m 4.5m 6.0m 7.5m 9.0m 10.5m

29 Thumb operation (Optional) 30 Lifting capacity

31 Operating the attachments 32 Position of checking hydraulic oil level

33 Machine lifting (optional) 34 Battery position

35 Notice attachment 36 Noise level, internal cabin noise (optional)

37 Greasing point 38 Optional pedal operation (optional)

39 Noise level, outdoor noise (optional) 40 Lubrication chart

41 Emergency exit 42 Attaching point for lashing / tying down

43 Machine weight and width (optional)

The USA federal clean air act

The following acts and the causing thereof are prohibited:

The law provides a penalty of up to $2,500 for each violation.

An example of a prohibited modifications is the recalibration of the

You should not make a change to an EPA-certified non-road en-

Normal non-road engine use

Non-road engine maintenance

Volvo CE recommends that the purchaser use the service pro-

In order to document that the proper regular maintenance has

Service performed by your local dealer

For regular scheduled service or maintenance, it is advisable to

Engine working conditions and ambient temperature influence the

In cold weather conditions, below 32 °F (0 °C), the use of lighter

To avoid excessive deposit formation and to minimize the emis-

Check the condition of the fuel hoses for:

Check the condition of the fuel tank:

Check the turbocharger:

1 Front instrument panel (IECU)

2 Right instrument panel

3 Upper instrument panel

5 Rear instrument panel

Front instrument panel (IECU)

1 Central warning lamp 14 Air cleaner clogging warning indicator

1 Central warning lamp

2 Engine coolant temperature gauge

3 Fuel level gauge

4-10 Not used

11 Engine oil pressure warning indicator