Volvo EC210B User manual
E(Z1OB
Ser. No 14132-
VOWO
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
California
Proposition 65 Warning
Battery posts, terminals and other related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and other
reproductive harm.
Wash hands after handling.
Contents
>
Presentation
>
Instruments and controls
>
Operating instructions
>
Safety when servicing
Service and maintenance
Specifications
Alphabetical index
OPERATOR'S MANUAL
E(21OB
Foreword
This Operator Manual is intended as a guide for the correct use
and maintenance of the machine. Therefore, study it carefully
before starting and operating the machine, or before carrying
out any preventive maintenance.
Keep the manual in the intended place in the cab so that it is
always at hand. Replace it immediately, if it is lost.
The manual describes the applications for which the machine
primarily is intended and is written to apply to all markets. We
therefore ask you to disregard the sections which are not appli-
cable to your machine or to the work for which you use your ma-
chine.
Many hours are spent on design and production to make a ma-
chine that is as efficient and safe as possible. The accidents
which occur in spite of this, are mostly caused by the human
factor. A safety conscious person and a well maintained ma-
chine make a safe, efficient and profitable combination.
There-
fore, read the safety instructions and follow them.
NOTE:
This manual has been adapted to cover all markets. Disre-
gard optional or special equipment included for various
markets, which are not applicable to your machine.
We continually strive to improve our products and to make them
more efficient through changes to their design. We retain the
right to make these improvements on products which have al-
ready been delivered.
We also retain the right to change data and equipment, as well
as instructions for service and maintenance without prior no
tice.
Safety regulations
It is the operator obligation to know and follow the applicable
national and local safety regulations. The safety instructions in
this manual only apply to cases when there are no national or
local regulations.
WARNING!
The symbol above appears at various points in the
manual together with a warning text. It means:
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.
Get to know the capacity and limits of your machine!
Ref. No. : VOE 21B1001632
The original language Is English.
Printed in Korea 2006.02
Copyright © 2006, Volvo Construction Equipment Customer Support. All rights reserved.
Foreword
This symbol, which is shown at various places in the Operator's
Manual together with a warning statement, means:
WARNING!
Warning, be alert! Your safety is involved!
To ignore the risks may lead to an accident, serious
injuries.
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.
Get to know the capacity and limits of your machine!
Handling and maintenance of the machine
Volvo Construction Equipment is responsible only if:
— the machine has been used in a correct way and been main-
tained in accordance with the instructions contained in the Op
-
erator's Manual and Service Manuals.
— prescribed service and prescribed inspections have been car-
ried out at the stated points in time.
— the recommended lubricants according to the manual have
been used.
—
fitted security seals are unbroken or that adjustments and ref it-
ting of security seals has been carried out by an authorized
dealer workshop.
— all modifications and repairs performed, and methods used,
have been prescribed by Volvo.
— only Volvo genuine spare parts/accessories, or genuine spare
parts/accessories which meet Volvo's requirements, have been
used.
A
WARNING!
An operator of an excavator must have sufficient
knowledge and instructions before helshe operates the
machine.
An untrained operator can cause serious injuries.
Never use an excavator which has no Operator's Manual.
Understand the warning plates and symbols on the
machine and its operator instructions before you begin to
use the machine.
Foreword
Communication equipment, installation
3
Communication equipment,
installation
IMPORTANT!
All installation of optional electronic communication equip-
ment must be performed by trained professionals and in
accordance with Volvo Construction Equipment instructions
applicable to the specified machine.
Protection from electromagnetic interfer-
ence
This machine has been tested in accordance with EU directive 89/
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 excavator, with a
permanently antenna fixed on the cab, installed as advised by the
manufacturer. If a portable mobile telephone is used, note that this
can constantly transmit information to its base station, even when
the telephone is not used. For this reason, it should not be located
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.
Foreword
4
Communication equipment, installation
Contents
5
Contents
Foreword
1
Communication equipment, installation
3
Contents
5
Presentation
7
General
7
Plates and decals
12
Service
40
General information
41
Instruments and controls
45
General
45
Instrument panel
46
Switches
60
Controls
73
Selecting valves for optional parts
76
Operator seat
79
Safety locking system
81
Cab window
82
Fire extinguisher and emergency exit
86
Fuel accessory pump
87
Air conditioner/heater (option)
88
Radio and cassette player
90
Operating instructions
91
Introduction
91
Running-in instructions
92
Whole body vibrations
93
Safety and responsibility
95
Transporting the machine
100
Disassembling for transportation
102
Counterweight installation
106
Changing bucket
109
Hydraulic quickfit (si)
110
Selecting track shoe
113
Hose rupture valves (option)
114
Before operating
116
Start switch
119
Starting engine
121
Operating machine
123
After operating
126
Parking
127
Towing method
128
Anti-vandalism
129
Working with bucket
130
Escaping from swampy ground
134
Signalling diagram
135
Lifting objects
139
Optional parts
140
Contents
Safety when servicing
145
Introduction
145
Service position
146
General
147
Handling lines, tubes and hoses
150
Measures to prevent fire
151
Batteries
156
Air conditioning
159
Use handholds and steps for climbing on / off
161
Service and maintenance
163
Engine
163
Fuel system
166
Intercooler
170
Turbocharger
170
Air cleaner
171
Cooling system
173
Electrical system
177
Hydraulic system
182
Swing drive unit
187
Track drive unit
189
Handling accumulator
191
Swing gear and bath, greasing
192
Air conditioner
196
Track slack
197
Replacing bucket teeth
200
Lubrication
203
Lubrication and service chart
204
Periodic replacement of safety critical parts
209
Specifications
211
Recommended lubricants
211
Coolant
212
Capacities, Intervals between changes/replacements
213
Specifications
214
Cab, specifications
216
Dimensions
217
Bucket & arm combination
219
Digging forces with direct fit bucket
224
Digging forces with direct fit bucket
225
Working ranges
226
Care and maintenance journal
228
Alphabetical index
239
Presentation
General
7
Presentation
S83051A
General
Intended use
The machine is intended to be used in the way described in this
manual. If the machine is used in another way or in potentially dan-
gerous environments, e.g. explosive atmosphere or areas with
dust containing asbestos, special safety regulations must be fol-
lowed and the machine be equipped for such use.
Contact the manufacturer/dealer for further information.
Engine
The engine is a straight six cylinder, four stroke, direct injection
diesel with 5.7 liter cylinder volume, turbocharged, intorcooled and
electronically controlled fuel injection by EMS (Engine Manage-
ment System), Volvo engine D6DEAE2
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 vehicle information for the operator.
Presentation
8
General
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 consists 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 a four spool block, a three spool 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 the servo hy-
draulic system.
Track motor and gearbox
The track motor is a variable swash, axial piston design that in-
cludes the brake valve assembly and parking brake. The rear
flange contains the counterbalance valve, check valves, crossover
relief valves and displacement changeover valve.
The gearbox composed of sun gear, planetary gear, pinion gear
and housing.
Swing motor and gearbox
The rotary group consists of cylinder block and nine pistons as-
sembles located in the cylinder. Piston assemblies are guided by
return plate and spring so they slide smoothly on the swash plate.
The cover section has a relief valve for cushioning and an anti-cav-
itation valve to prevent cavitation.
Gearbox is composed of sun gear, planetary gear, pinion gear and
housing. Power supplied to the output shaft of the swing motor re-
duces the motor speed through the sun gear and planetary gear
and the high torque is transmitted to the pinion gear.
Presentation
General
9
Cab
The cab has a heating and ventilation system with defrosting from
front and rear windows. Air conditioning is available as an option.
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 protective cab according to FOPS and
FOG standards, see
Protection from falling or scattering mate
-
rialon page 99. FOPS is an abbreviation of Falling Object Protec-
tive Structure (roof protection) and FOG is an abbreviation 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 ware of these regula-
tions.
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.
Model/Type
Product
Identification
Number
Machine mass Kg
Engine net power KW
Manufacturing year
VOLVO •
S83052
Presentation
10
General
•
Volvo Construction E
•
ui
•
mentO
Volvo Construction Equipment Korea Ltd.
1, Guehyun-Dong, Changwoo-City, Kyuoqrram, Korea 641-430
CE marking and Declaration of Conformity
NOTE:
Applies only to machines marketed within the EU/EEA.
This machine is CE marked. This means that, when delivered to
the customer, the machine meets the applicable "Essential Health
and Safety Requirements", according to the EU Machine Safety
Directive. Any person carrying out an alteration that affects the
safety of the machine, is responsible for the consequences.
The machine is supplied together with a Declaration of Conformity
with the EU Machine Safety Directive. The documentation is a
valuable document, which should be kept safe and always be kept
in the machine.
If the machine is used for purposes or with other attachments than
described in this manual, safety must at all times and in each sep-
arate case be maintained. The person carrying out such action is
also responsible for the action which, in some cases, may require
a new CE marking and the issue of a new EU Declaration of Con-
formity.
Volvo CE is only responsible for a machine which is used with
approved equipment and spare parts specified by Volvo CE.
Presentation
General
11
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 on "Electromagnetic compatibility", 89/336
/ EEC, provides 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.
nsrdee.vtnit5Oi5flF)
MANUFACTURED IN
KOREA
•
VOLVO
.,...•
Volvo Construction Equipment Korno Ltd.
CE
•
VOLVO
S
MANUFACTURED IN KOREA
VOLVO
1A
lB
s1!~.
i
j.I%.)LL.flI
Volvo Construction Equipment Korea Ltd.
MANUFACTURED
IN
KOREA
VOLVO
lc
STA.1IrL.Ij%.]I}oftl
[.ti[.t,..LUJ!.
Volvo Constrclion Equipment Koren Ltd.
•
VOLVO
ill 1
.
1 lii
IkL.J%.IIo1lA
L.iL.]s.LUJ
Volvo CoostruvAon Equipment Korea Ltd.
Volvo Consttuotine Equipment Korea Ltd.
Presentation
12
Plates and decals
Plates and decals
Product plates
This illustration and text below show which product plates are
found on the machine.
When ordering spare parts and when making enquires by tele-
phone or correspondence, the model designation and Product
Identification Number (PIN) should be stated.
Presentation
Plates and decals
13
1 Product plate with Product Identification Number,
PIN
for the
complete machine (shows the model, serial numbers, machine
weight, engine output and when applicable CE approval). The
plate is positioned on the right side of the upper frame.
1A: Product plate, version for EU market
1 B:
Product plate, version for North America, International mar-
ket
1C: Product plate, version for Middle East market
2 The engine type designation, part and serial numbers are
stamped into both sides of the cylinder block.
3 The quickfit nameplate is attached on the outside of the quick-
fit. (shows part number and weight)
4 The bucket nameplate is attached on the top of the bucket.
(shows the bucket model order Number, serial number, bucket
part number, rated capacity, weight, cutting width, tooth part
number and adapter part number)
4
WARNING
A
Presentation
14
Plates and decals
Information and warning plates
The following depicts various warning and information texts that
may be affixed to the machine and their mounting location. The op-
erator must know and pay attention to the warning and safety in-
formation on each decal and plate. Decals / plates that are lost,
damaged, illegible, painted over or not clearly visible must be re-
placed immediately.
The part number (order number) of the respective plates / decals
can be found in the Parts Catalogue.
1 Do not start the engine
S60606
2 Safety locking
See
Safety locking system on page 81.
àWARNING
S82335
4
'A WARNING
4
r
2M1TF1) 0
-lw
4MllsFrJ 1-55W
SM (2OFTI 55- 500W
Presentation
Plates and decals
15
3 Do not unscrew the recoil spring
See
Inspecting and adjusting the track slack on
page
197.
4 Emergency exit
See
The emergency hammer (B) should be used in an emer-
gency situations,
on page
86.
5 Warning, high voltage
See
Never approach a high voltage wire
on page
98.
6 Warning when operating the optional attach-
ment
If the machine
is
equipped with an adjustable boom or quickfit
bucket, the digging arm with
its
boom fully retracted can damage
the operator cab.
WARNING!
If the machine is equipped with any other attachments
(quickfit, hammer, large bucket,...), that may damage the
operator cab and other structure.
7 Operating optional attachments
I
4
pc
TP
\t3
/r
S82004
S80599
S80954
S60602A
S81209B
AWAR*IG
4
4'
1%
F
S
Presentation
16
Plates and decals
8 Lifting capacity table
S83160A
F: Lifting capacity over the front or rear of the machine
S : Lifting capacity over the side of the machine
H : Height
R: Reach
MR : Maximum reach
Presentation
Plates and decals
17
Long Crawler (LC)
Counterweight
=
9259 lb (4200 kg)
Boom
=
18 ft 3 in (5.57 m)
Arm
=
8 ft 2 in without bucket
Shoe = 600 mm (24 in)
(Unit: Ibs)
R Oft 51t lOft 15ft
20ft 251t 30ft
MR
H
25ft
F
*16410
*13770 (@17,55ft)
S
*16410 *13770
20ft
F
-
*16540
*14620
*12500 (@21,91 ft)
S
*16540
11300
9630
l5ft
F
*25830
*18570
*15220
12210 (@24,49 it)
S
*25830 17290 11000
7890
lOft
F
*21510 *16350
11620
11020 (@25,84 if)
S
16010
10480
7460
7070
5ft
F
*23490
15940 11390
10630 (@26,17ft)
S
14900
9970
7250
6770
Oft
F
*23210
15550
11230
10920 (@25,51 ft)
S
14370
9630
7110
6920
-Sit
F
*23850 *20790
15450
*11940 (@23,77ft)
S
*23850 14290 9540
7610
-loft F
*16040
*11340
*10450 (@20,69ft)
S
14560
9760 9370
-151t
F
S
S86604
NOTE:
1.
The above loads are in compliance with SAE and ISO Hy-
draulic Excavator Lift Capacity Standards.
2.
They do not exceed 87% of hydraulic lifting capacity or 75%
of tipping load.
3.
Rated loads marked with an asterisk(
*)
are limited by hy-
draulic capacity rather than tipping load.
Presentation
18
Plates and decals
Long Crawler (LC)
Counterweight
=
9259 lb (4200 kg)
Boom = 18 ft 3 in (5.57 m)
Arm = 9 ft 6 in without bucket
Shoe = 600 mm (24 in)
(Unit: tbs)
R Oft 5ft lOft
l5ft
2Oft
25ft 30ft
MR
H
30ft F
*12760 (@12,34ft)
S
* 12760
25ft F
*14060
*10000 (@19,43ft)
S
*14060
*10000
20ft F
*14180 *13890
*9160 (@23,43ft)
S
*14180
11510
8750
15ft F
*17340
*17540 *14640
*11560
*8950 (@25,85ft)
S
*17340 *17540
11180
7760
7310
lOft
F
*20680
*15920
11730
* 9130 (@27,14ft)
S
16340 10630 7550
6610
5ft
F
*23130
16050
11440
* 9680 (@27,45ft)
S
15130 10070 7300
6340
Oft F
*12480 *23500 15600
11230
10160 (@26,82ft)
S
*12480
14440
9670
7100
6450
-5ft F
*22470 *21680
15420
11200
-
11100 (@25,18ft)
S
*22470
14260
9510
7080
7020
-lOft F
*22620
*17610 *12910
*10390 (@22,29ft)
S
*22620
14430
9630
8390
-l5ft
F
S
886605
NOTE:
1.
The above loads are in compliance with SAE and ISO Hy-
draulic Excavator Lift Capacity Standards.
2.
They do not exceed 87%
of
hydraulic lifting capacity or 75%
of
tipping load.
3.
Rated loads marked with an asterisk( *
)
are limited by hy-
draulic capacity rather than tipping load.
Table of contents
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